Client Background

A major 250,000-square-foot fabrication facility in Illinois operates as a critical manufacturing hub for industrial components and custom metalwork. The facility runs multiple production lines featuring CNC machines, automated welding systems, plasma cutting tables, and precision fabrication equipment. Operating on tight delivery schedules with just-in-time manufacturing commitments, the plant serves aerospace, automotive, and heavy equipment sectors where production delays directly impact customer contracts and revenue streams.

The Challenge

The fabrication facility faced critical electrical maintenance and reliability issues that threatened production targets:

  • Costly Downtime: Unplanned equipment failures were costing thousands of dollars per hour in lost production, with cascading impacts on delivery schedules
  • Understaffed Maintenance Team: The existing in-house electrical team lacked sufficient capacity to handle both preventive maintenance and emergency repairs
  • Response Time Gaps: Critical equipment failures required immediate troubleshooting expertise that wasn’t always available on all shifts
  • Aging Infrastructure: Outdated power distribution systems and control panels needed systematic upgrades without disrupting production
  • Specialized Equipment Knowledge: Complex CNC and automated fabrication systems required electricians with specific industrial experience

The Solution

Advastar implemented a comprehensive electrical staffing solution tailored to the facility’s 24/7 production demands:

  • Rotating Crew Deployment: Established a reliable rotation of contract service electricians providing coverage across all shifts and weekends
  • Preventive Maintenance Program: Implemented scheduled maintenance protocols for CNC machines, robotic welders, and automated fabrication equipment
  • Rapid Troubleshooting Response: Deployed electricians skilled in industrial fault diagnosis and emergency repair procedures
  • Infrastructure Modernization: Managed installation of upgraded power panels, motor control centers, and updated wiring systems
  • Specialized Technical Expertise: Provided electricians with specific experience in PLC troubleshooting, VFD programming, and industrial control systems

The Outcome

Advastar’s electrical staffing solution delivered measurable improvements in facility operations and reliability:

  • Downtime Reduction: Achieved 15% reduction in unplanned downtime within the first 90 days through proactive maintenance and faster response times
  • Production Efficiency Gains: Increased overall equipment effectiveness through systematic preventive maintenance scheduling
  • Long-Term Partnership: Client extended Advastar’s electrical service contract based on proven performance and reliability
  • Cost Savings: Reduced overtime expenses for in-house staff while maintaining superior electrical system reliability
  • Enhanced Safety Record: Zero electrical safety incidents throughout the contract period through proper procedures and qualified personnel