Latest / The Operations Podcast with Fexingo: Process, People, and Profit in Modern Business
How a Steel Mill Cut Unplanned Downtime by 80 Percent
Lucas and Luna examine how a midsized steel mill in Indiana slashed unplanned equipment downtime by 80 percent over 18 months. They break down the specific predictive maintenance framework the mill adopted—vibration analysis, thermal imaging, and a tiered response protocol—and walk through the financial impact: from $12 million in annual lost production to under $2.5 million. The episode digs into why most predictive maintenance programs fail and what this mill did differently: they tied sensor data directly to a simple traffic-light dashboard that frontline operators owned. Lucas and Luna…
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