Restoring Control and Performance at the Momence Plant

Case Study: Restoring Control and Performance at the Momence Plant

The Challenge

When ReliabilityX began working with the Momence Plant, the situation was critical. The facility was operating with an ineffective maintenance and operations strategy. Overall equipment effectiveness (OEE) had dropped to 40 percent, and the plant was entrenched in a reactive culture. Leadership and maintenance teams lacked the training and skill sets needed to drive improvement. These issues contributed to a manufacturing variance deficit of $900,000.

The plant was losing time, money, and confidence. Every shift was marked by uncertainty, and the operations team was stuck in a cycle of short-term fixes and long-term losses.

The Solution

ReliabilityX approached the challenge with a hands-on, strategic plan. Their team developed a comprehensive maintenance strategy focused on predictive technologies, inventory optimization, and systemic loss elimination. They worked directly with plant leadership and maintenance staff to build a proactive, problem-solving culture.

Key actions included:

• Implementing predictive maintenance tools to reduce downtime and improve reliability
• Streamlining on-hand parts inventory to reduce waste and improve responsiveness
• Delivering targeted training to leadership and technicians to build operational capability
• Spending time on the floor to resolve minor stops and address root causes in real time

This was not a theoretical exercise. It was a practical, floor-level transformation.

The Results

The impact was substantial. The Momence Plant’s OEE rose from 40 percent to nearly 65 percent. Operational efficiency improved across the board, and the plant began recovering from its manufacturing variance deficit. The shift from reactive to proactive operations created measurable financial and cultural gains.

The plant is now positioned for sustained performance, with stronger leadership, better systems, and a renewed sense of control.

Conclusion

ReliabilityX helped the Momence Plant move from instability to operational strength. Their approach combined strategic planning with direct engagement, resulting in improved performance and financial recovery.

If your plant is facing similar challenges, ReliabilityX can help. Contact us at ask@reliabilityx.com or click here.