A global manufacturer operating 18 plants across 7 countries was losing $15.8M annually to unplanned downtime—with each facility running its own disconnected maintenance system. After standardizing on a single cloud CMMS platformthey reduced unplanned downtime by 41% and saved $6.2M per year. Here's the blueprint.
Multi-plant manufacturers face a unique challenge: every facility develops its own maintenance culture, tools, and processes over time. This fragmentation creates blind spots, inconsistent qualityand ballooning costs. This case study shows how one manufacturer unified 18 plants into a single, data-driven maintenance operation.
How a Manufacturer Standardized Maintenance Across 18 Global Facilities
From Fragmented Operations to Unified Global Maintenance Excellence
The Challenge: 18 Plants, 18 Different Systems
Fragmented Maintenance Operations
The Situation
The manufacturer operated 18 production facilities across the US, Mexico, Germany, India, China, Brazil, and Thailand. Each plant used a different combination of legacy CMMS, spreadsheets, or paper-based tracking. Corporate leadership had zero real-time visibility into maintenance performance, spare parts inventory, or equipment reliability across the network. PM compliance ranged from 38% to 71% depending on the facility.
Financial Impact
- Unplanned downtime costing $15.8M annually across all 18 plants
- Spare parts overstocking of $4.1M due to no cross-plant inventory visibility
- 3 plants failed regulatory audits in one year due to inconsistent documentation
- Maintenance cost per unit varied 3x between the best and worst-performing plants
The Solution: One Global CMMS Platform
Phased Global Rollout Strategy
Rollout Timeline
Running Multiple Facilities With Disconnected Maintenance Systems
See how a unified CMMS platform gives you real-time visibility across every plant—standardizing work orders, PM schedules, and spare parts inventory from a single dashboard.
The Results: Measurable Impact Across 18 Plants
Global Savings Breakdown
Annual Savings Breakdown
Before vs. After: Global Performance Metrics
Performance Comparison
4 Strategies That Drove Global Standardization
Replicable Tactics for Multi-Plant Operations
What Made the Difference
Is This Achievable for Your Manufacturing Network
High-Impact Candidates:
Plants using different CMMS, spreadsheets, or paper-based tracking with no unified view
Wide performance gaps between your best and worst-performing facilities
Recurring equipment failures costing production output across multiple sites
Getting Started Is Simple:
Select one high-performing, one average, and one struggling facility for fastest proof of value
Unify PM schedules, work order categories, and asset naming conventions before scaling
Get technicians on mobile apps immediately—adoption drives all downstream results
Start Your Free Trial — No Credit Card Required
See how OxMaint helps multi-plant manufacturers unify maintenance operations, standardize PM schedules, and gain real-time visibility across every facility. Get started in minutes, not months.
Need a customized multi-plant savings analysis Chat with our manufacturing solutions team — We'll estimate your potential savings based on the number of facilities and your current maintenance spend.
Key Takeaways: Multi-Plant Maintenance Standardization
- 41% less unplanned downtime achieved by standardizing preventive maintenance across all 18 facilities
- $6.2M annual savings across downtime reduction, spare parts optimization, labor efficiency, and compliance
- 94% PM compliance up from an inconsistent 38-71% range with unified templates and automated scheduling
- 89% technician adoption in 8 weeks using a mobile-first, multilingual CMMS platform
- MTTR cut from 14.6 to 5.2 hours through cross-plant knowledge sharing and standardized workflows
- Quick wins matter: A 3-plant pilot delivered 18% downtime reduction in just 3 months
Ready to Standardize Maintenance Across Your Facilities
Schedule a free consultation to see how a unified CMMS platform can eliminate fragmented operations, reduce downtime, and save millions across your manufacturing network.
