In the manufacturing world, summer shutdowns are often treated as necessary pauses—moments to rest, reset, and perhaps catch up on overdue maintenance. However, forward-thinking operations leaders view these resets as something far more valuable: a rare, time-bound opportunity to take control of performance.
When production stops, the clock starts ticking. You have a narrow window to realign equipment, correct nagging inefficiencies, and modernize facility systems—all without disrupting output. And when this is done right, the results extend well beyond summer.
C&W Services helps manufacturers across North America use these shutdowns to unlock new levels of efficiency. This is how we help our clients make it happen:
Why 74% of Equipment Defects Are Preventable
Most facilities assume their preventive maintenance (PM) programs are sufficient because the equipment appears to be running smoothly. But “running” isn’t the same as optimal. Minor misalignments, outdated PM routines, and unchecked failure points quietly chip away at throughput and reliability until a costly disruption forces action.
We saw this firsthand with the world’s largest e-commerce retailer. Across 183 fulfillment centers, robotic palletizers were causing persistent over-height kickouts despite regular maintenance. It wasn’t until the client used a scheduled shutdown to conduct a complete preventive maintenance verification that the problem was fully understood—and resolved.
By benchmarking their existing routines against manufacturer specifications and industry best practices, and then adjusting accordingly, they achieved a 74% reduction in daily defects. They also forecasted $1.6 million in annualized savings across the network.
These results were about both maintenance and alignment. A proactive strategy ensures that maintenance is performed correctly, to the standards for which the equipment was designed.
The $1.6M Payoff for Addressing Failure Points
Every plant has its problem areas. You know where they are: the conveyor that consistently backs up. The palletizer that rejects too many loads. The system that just won’t stay calibrated. The challenge is never the awareness—it’s finding time to fix these issues with the required depth. That’s why summer shutdowns present great opportunities.
Instead of doing a generic PM sweep, leading facilities use their summer windows to target known failure points with surgical precision. In the e-commerce case, the team focused specifically on over-height kickouts—a persistent issue previously accepted as a routine loss. During the shutdown, C&W Services isolated that failure mode and implemented corrective calibration. The result was a 74% reduction in defects caused by that single issue.
Even more significant was the broader impact on quality. With improved PM and system calibration, the client achieved a 3.02% decrease in total quality-related kickouts—a measurable improvement in first-pass yield during peak operations.
Facilities that act now can eliminate these hidden drains on productivity before they resurface during the year’s busiest months.
Automation Projects That Cut Costs and Boost Reliability
While equipment maintenance focuses on reliability, building systems control the conditions that make reliable operations possible. HVAC, lighting, air quality, and energy systems all play critical roles in uptime and efficiency, but they often go overlooked until something breaks.
Summer shutdowns provide a unique opportunity to update or fine-tune building automation systems (BAS) without disrupting production. C&W Services helps clients implement smarter control systems that automatically monitor energy use, adjust to real-time conditions, and reduce overall operating costs.
By upgrading automation during a shutdown, facilities avoid costly interruptions and ensure the systems are calibrated from the start. That means less energy waste, more stable environmental conditions, and longer life for mechanical systems.
We’ve seen clients lower utility bills and reduce system failures simply by optimizing their automation controls during summer windows. The benefits continue throughout the year, especially during winter peaks when comfort, performance, and cost all collide.
Smart Investments That Keep Paying Off
The most important improvements aren’t the ones you see immediately—they’re the ones that pay off all year. Once building systems are optimized and automated, they work around the clock to adjust lighting, climate, and airflow without requiring human intervention. This type of control reduces utility costs while also extending equipment lifespan through predictive adjustments and early detection of issues.
Instead of waiting for problems to appear, these systems help prevent them. When combined with a refined PM strategy, they create a self-reinforcing cycle of operational stability. That’s how you turn a summer maintenance project into a year-round competitive advantage.
Conclusion: Don’t Waste the Downtime
Every facility gets a summer pause. The difference is what you do with it. Reactive plants rush through checklists and hope for the best. Strategic ones plan, prioritize, and upgrade. This is an opportunity for both transformation and maintenance. But the window is closing.
C&W Services is ready to help. Whether you need preventive maintenance verification, failure point targeting, or intelligent automation upgrades, our team can turn your summer shutdown into a lasting performance edge.
Turn planned downtime into your competitive advantage. Contact us today.
