Imagine slashing production losses by 60% and reducing critical asset failures by 40%. For a wet corn mill facility in Cedar Rapids, Iowa, processing 100,000 bushels daily, these results went from aspirational to reality. In an industry where every hour of downtime impacts production and the supply chains of various products—corn gluten meal, high-fructose corn syrup, SEM, and Sweet Bran 60 cattle feed—such a shift represents a game-changer.
Start Strong with a Maintenance Resolution
Modern manufacturing thrives on precision. As a leading integrated facilities services company with over 600 clients across 600 million square feet, C&W Services understands that complex processes are nowhere more evident than wet milling. Corn transitions through steeping, grinding, separation, and conversion phases, each relying on highly specialized equipment like centrifuges, rotary dryers, and conveyors. When one system fails, the ripple effects through production delays can substantially eat into the bottom line.
At Cedar Rapids, the 100-acre facility was plagued by mechanical failures in conveyors and rotary dryers, which led to substantial bushel losses and jeopardized product output. Recognizing the urgent need for a transformation, the plant partnered with C&W Services to craft tailored maintenance solutions that enhanced asset reliability, optimized performance, and reduced downtime. The partnership led to an unprecedented 60% reduction in bushel loss, improved product quality, and fewer disruptions across operations.
Building Success Through Facility Condition Assessments
Every transformation begins with a clear understanding of the challenge. At Cedar Rapids, this meant conducting a Facility Condition Assessment (FCA) to diagnose equipment issues, uncover inefficiencies, and create a roadmap for improvement. The structured FCA process provided a tailored plan in three critical phases:
1. Mobilization and Planning (30 Days):
We developed a customized strategy to address the plant’s unique challenges. This distinct plan for the Cedar Rapids facility included aligning maintenance priorities with the intricate interdependencies of equipment.
2. Data Collection (60 Days):
Experts evaluated the condition and functionality of critical assets like rotary dryers and conveyors. This phase uncovered visible damage and hidden inefficiencies that would escalate if unaddressed.
3 . Report Development (30 Days):
The final phase transformed raw data into actionable recommendations, guiding decisions on repairs, replacements, and preventive maintenance schedules. This detailed insight empowered the plant to focus resources effectively.
The 30-60-30 process is adaptable to the unique needs of each facility. C&W Services offers three types of FCAs—basic, intermediate, and comprehensive—ranging from foundational equipment assessments to in-depth evaluations that prioritize major repairs and capital projects. This flexibility ensures clients receive a solution aligned with their operational goals. (Each assessment delivers key benefits through our PAID approach: Prioritizing risk-based repairs and replacements, Auditing building equipment inventory, Identifying physical and functional deficiencies, and Diagnosing potential damage and safety hazards.)
From Strategy to Success: Real-World Impact
The Cedar Rapids plant turned strategic planning into measurable results through innovative maintenance approaches:
1. Real-Time Monitoring:
Real-time systems acted as the facility’s early warning system, tracking stress indicators and identifying potential failures before they could escalate. For example, monitoring conveyors allowed technicians to address minor issues that could have led to significant downtime, directly contributing to a 60% reduction in bushel loss.
2. Critical Path Optimization:
Maintenance routes were redesigned to focus on high-priority areas, ensuring technicians could address issues faster. By targeting choke points like rotary dryers, resolution times were significantly reduced, minimizing disruptions.
3. Tailored Preventive Maintenance (PM) Strategies:
Customized PM schedules ensured that maintenance efforts were focused where they mattered most. Equipment received attention based on actual usage and condition, avoiding redundant checks and reducing labor demands. This approach extended the lifespan of critical assets while keeping operations running smoothly.
A Blueprint for 2025: Turning Resolutions into Results
The Cedar Rapids transformation demonstrates what’s possible when a commitment to maintenance excellence becomes part of a facility’s culture. A 60% reduction in bushel loss is more than a statistic—it represents raw material savings, enhanced product output, and a reinforced role within the supply chain. With a 40% reduction in critical asset failures, the facility built a stronger, more resilient foundation for future growth.
The message for manufacturing facilities looking to thrive in 2025 and beyond is clear: the journey starts with understanding where you are today. With tools like comprehensive Facility Condition Assessments and tailored maintenance strategies, facilities can unlock their potential and achieve operational excellence that safeguards quality, efficiency, and profitability.
Ready to transform your facility’s maintenance? C&W Services can help you achieve a success story like the one in Cedar Rapids and gain remarkable results in your operations.
