Automotive & Industrial Components
From firefighting repairs to structured preventive maintenance
Logio partnered with Z‑Group’s Železárny Hrádek plant to redesign its maintenance organisation and processes so that the steel mill could support higher and more stable production performance.
Outcome
By rebalancing the ratio between corrective and preventive work, defining a clear maintenance structure and introducing new monitoring and planning processes, the plant reduced repair times, increased equipment availability and limited the frequency of production downtime.
Planned maintenance increase by
+0%
About Z‑Group Steel
Z‑Group Steel is a Czech metallurgical group that continues the long tradition of iron and steel production in Central Europe, with plants such as Železárny Hrádek and Železárny Veselí manufacturing tubes, bars, wires, special profiles and ingots for a wide range of industrial applications including energy, construction, engineering and automotive.
Founded in 1900 as Železárny Hrádek, today part of Z‑Group Steel.
Around CZK 2.1 billion in annual turnover.
Products exported to more than 45 countries.
Initial challenge
The Železárny Hrádek plant wanted to optimise its existing maintenance processes to support higher production performance and reduce the impact of equipment failures on output.
Project goal
The project aimed to shorten repair times and ensure higher availability of production equipment, which in turn would reduce the frequency of downtime, improve production KPIs and strengthen the company’s bottom line.
Solution
Maintenance strategy, organisation and processes redesign
Logio focused on shifting maintenance toward prevention, clarifying responsibilities and introducing new processes for planning and monitoring maintenance activities.
Solutions implemented
Maintenance Strategy & Planning
KPI Design & Performance Monitoring
Preventive & Predictive Maintenance
Impact
More reliable equipment, fewer production stops
Stronger preventive maintenance
Maintenance activities shifted towards prevention, improving the balance between corrective and preventive work by 50 %.
Shorter repair times
Clearer roles and streamlined processes help teams diagnose and fix equipment issues faster.
Higher equipment availability
Better planning and maintenance scheduling increase available production time for key equipment.
Fewer unplanned downtimes
New monitoring and planning processes reduce the frequency of unexpected production shutdowns.
Better production KPIs and profitability
Reduced downtime and smoother operation contribute to stronger production indicators and an improved bottom line.
Increase the reliability of your production lines
If unplanned downtime and firefighting maintenance slow down your plant, we can help you design a preventive maintenance strategy, organisation and KPIs that increase availability and production performance. Let us talk about what this could look like in your operation.
We tackled many supply chain challenges
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+10 % labor productivity in 2 months
Up to –30 % long‑term sickness expected
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Laufen reduced portfolio complexity by proposing the removal of 40% inefficient items and defined a supply chain control tower to coordinate end‑to‑end flow, with €5M savings potential identified.
−40% inefficient items proposed for delisting
€5M potential savings identified