Case
We reduced the maintenance costs of a premium coffee producer and exporter by more than 25%
Context
Company producing and trading premium green coffee for export, with farms in Minas Gerais. Diagnosis revealed high maintenance costs, high failure frequency, and long repair times — negatively impacting productivity and equipment availability.
Approach
Operational model changes
- New maintenance operational model;
- Increased preventive maintenance, significantly reducing corrective maintenance;
- Increased autonomous maintenance and extended mobile maintenance coverage.
Process improvements
- New management model with KPI dashboard and management processes;
- Maintenance process standardization and reduction of primary failure modes.
Resource adequacy
- Equipment and infrastructure, labor, and third-party services.
Results
- Maintenance cost reduction exceeding 25% of forecast;
- Preventive maintenance increase exceeding 57%;
- MTBF increase exceeding 77% and mean repair time reduction exceeding 14%;
- Tractor mean repair time reduction of 18%;
- Maintenance KPI dashboard implemented;
- Failure identification by subsystem and equipment;
- New maintenance management model.