Improving MTTR + MTBF levels to increase production for a large Indian global Pharma manufacturer.

Problem: 

Our esteemed client was an Indian multinational pharmaceutical company who raised deep concerns regarding the prolonged duration of their equipment repairs. To make matters worse, subsequent breakdowns occurred within three days of the repairs. 

The attrition issues resulted in trained OEM technicians leaving their positions. Among the remaining technicians, only one possessed the necessary expertise to handle the repairs of specialized equipment leading to over 150 hours of costly downtime for our client. 

After a thorough research, we discovered that Critical (SOPs) were not followed, resulting in significantly longer repair and maintenance durations. In fact, these durations often exceeded 50% more time than necessary.