Plan
Turn priorities into a clear operating plan.
Identify and plan work before it reaches the floor, with parts and steps ready.
USC Consulting Group / Maintenance & Reliability
Planned work. Dependable equipment.
We connect maintenance planning and scheduling to production through one operating rhythm, so reliability becomes a daily discipline.
The management operating system
How the eight disciplines apply to maintenance & reliability.
Every improvement runs through the same connected cycle. Here is what each discipline looks like in this part of the operation.
Schedule
Make the plan workable day to day.
Agree one weekly schedule with production so maintenance windows are protected.
Assign
Make ownership clear.
Assign planned jobs to crafts and crews with realistic hours.
Execute
Understand how work actually gets done.
Observe how crews work, wait, and travel to understand wrench time.
Follow Up
Keep commitments visible.
Close out work orders properly and review schedule breaks every week.
Report
Give people a useful view of performance.
Report schedule compliance and planned versus reactive work clearly.
Analyze
Use evidence to understand what is driving results.
Find repeat failures and the conditions behind them.
Improve
Turn what the team learns into better ways of working.
Shift effort from emergencies to prevention, one asset class at a time.
How we work
Built with your team, not about it.
Understand before recommending
Work from facts, live examples, and operational evidence
Involve the people who own the process
Build with the client, not about the client
Lead with curiosity, not diagnosis
Treat the review as learning, not auditing
02 / Maintenance & Reliability
Planned work. Dependable equipment.
We connect maintenance planning and scheduling to production through one operating rhythm, so reliability becomes a daily discipline.
- The challenge
- Unplanned failures drive the schedule. Backlogs grow, parts are hard to find, and maintenance and production work from different priorities.
- What USC does
- We build work identification, planning, scheduling, and execution routines with your crews, and tie them into the daily production review so priorities are agreed once.
- What changes
- Planned work increases, repeat failures fall, and maintenance spend is directed by data rather than emergencies.
How we measure progress:
- Schedule compliance
- Planned vs. reactive work
- Mean time between failures
Client results
Maintenance & Reliability case studies
Food & Beverage
$3Min annualized savings from throughput, yield, labor and sourcing
Dessert manufacturer adds capacity and cuts $3M in annual cost without new capital
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Aerospace & Defense
$5Min annual maintenance savings
Airline saves $5M a year by cutting maintenance cycle times 20%
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Food & Beverage
$2M+in annualized labor savings
Dessert maker cuts $2M+ in annual labor cost and lifts throughput to $58M
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Manufacturing
$10M+in annualized operating savings
API maker saves $10M+ a year after losing its largest customer
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Manufacturing
$4.2Min maintenance savings across three plants
Cement maker saves $4.2M across three plants by cutting maintenance costs 20%
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Energy & Utilities
$3Min annual overtime savings
Waste-to-energy producer saves $3M a year by cutting overtime across U.S. plants
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Mining & Metals
$1.2M+in annual savings realized
South American gold mine realizes $1.2M+ a year with employee-led improvement
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Food & Beverage
$8.1Min gains at the pilot complex, with no new capital
Turkey processor gains $8.1M at its pilot complex without new capital
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Aerospace & Defense
$22M+in financial returns
Major airline returns $22M+ by standardizing hangar operations without adding resources
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Food & Beverage
Repeat client$16Min annualized benefits
Pork producer gains $16M in annualized benefits from yield, labor and overtime
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Mining & Metals
24%increase in ore throughput over baseline
Gold producer raises ore throughput 24% with an operating system for mine and mill
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Mining & Metals
23%reduction in mine cost per ton
Copper mine cuts cost per ton 23% and mines 22% more tons
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Aerospace & Defense
6%increase in aircraft availability
Helicopter operator raises fleet availability and dispatch reliability 6%
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Logistics
Repeat client43%increase in cars shipped
Railcar lessor ships 43% more cars from its maintenance shops
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Aerospace & Defense
30%improvement in discrepancy repair performance
Military aircraft maintainer improves discrepancy repair performance 30%
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Mining & Metals
9.7:1return on investment
Gold miner's highest-cost site becomes its lowest-cost, with a 9.7:1 return
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Mining & Metals
66%increase in equipment availability
Copper-zinc miner raises equipment availability 66% with a 14:1 return
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Mining & Metals
15%increase in total tonnes