How Magna Plastcoat gained 18 months of advance warning on critical equipment failure.
An automotive parts manufacturer running 40 injection moulding machines. Frequent breakdowns. No way to see failure coming. Until now.”
About
Industry: Automotive Parts Manufacturing
Location: Confirm!
Sytems: Injection Moulding • Thermal Heating • Production Equipment
We are now able to determine a year and a half in advance before thermal actually goes bad. Less downtime, less wear and tear on our machines.
– James Draper. Maintenance area leader, Magna Plastcoat
The Problem
Magna Plastcoat’s facility runs on 40 injection moulding machines producing automotive components. Breakdowns were frequent, maintenance was reactive, and there was no way to know a machine was struggling until it stopped.
The Approach
Renteknik deployed monitoring across every critical asset — non-invasive, no disruption to production. Real-time performance data started revealing what the maintenance team couldn’t see: thermal signatures trending toward failure, months before breakdown.
The Results
Failures detected 18 months in advance. Maintenance shifted from crisis to schedule. ~$2M in operational savings identified, with $1.25M projected annually.
Operational savings identified in year one
Projected annual savings going forward
An automotive parts manufacturer running 40 injection moulding machines. Frequent breakdowns. No way to see failure coming. Until now.”
01
Always one step ahead
When failure stopped being a surprise, everything changed.
- Maintenance scheduled around production, not against it
- More machines attended before problems escalated
- Less unplanned downtime, less wear, more parts produced
- ~$2M in operational savings. $1.25M projected annually.
Parameters set across every monitored asset. When equipment drifts outside expected range, the team gets notified — before it becomes a breakdown.
Not a report after the fact. A signal in time to act.