Quvara was producing critical plastic medical components, operating 24/7 under strict regulatory requirements. Despite strong production demand, the site faced persistent operational challenges, including frequent unplanned stoppages, rising maintenance costs, and increasing customer pressure to meet On-Time-In-Full (OTIF) delivery targets.
Technicians were spending the majority of their time responding to breakdowns, limiting their ability to focus on improving long-term equipment reliability.
The operation was heavily reliant on reactive maintenance practices, resulting in:
Together, these issues created variability in equipment performance, reduced operational predictability, and increased both cost and compliance risk.
The approach taken was to design and implement a structured, risk-based preventative maintenance system, transforming the site from reactive to proactive operations.
A comprehensive maintenance strategy was established, including:
A digitally enabled PM scheduling system was implemented to ensure consistency and control, featuring:
To improve execution and compliance, structured work management systems were introduced:
Spare parts management was also transformed through:
A continuous improvement framework was embedded, incorporating:
Operator engagement was enhanced through the introduction of basic autonomous maintenance tasks, enabling early detection of issues and reduction of minor stoppages.
Quvara leveraged its cross-functional expertise to deliver and sustain the programme:
Quvara maintained full accountability for programme leadership and governance, ensuring equipment performance, budget control, and regulatory compliance were consistently achieved.
The implementation of the preventative maintenance system delivered measurable operational improvements:
Overall, the site transitioned to a controlled, data-driven maintenance model, improving reliability, reducing cost, and enabling sustainable operational performance.
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Our engineering and validation teams can implement rapid, low-risk solutions that increase capacity within tight timelines.
We design solutions that increase effective capacity using existing infrastructure, minimising capital investment and avoiding long validation cycles.
All Quvara solutions are developed within a fully compliant framework, ensuring scalability without compromising quality or regulatory standards.
Our in-house engineering, quality, and manufacturing teams work together to design, validate, and deploy solutions at pace.
We focus on automated, integrated solutions that enhance output without increasing labour requirements.
We design staged, low-risk implementation plans that protect ongoing production while scaling capacity.
Quvara combines engineering insight, validated manufacturing, and scalable infrastructure to support your growth, now and long term.