Optimizing Asset Lifespans Through Combined Frontline and Predictive Maintenance

#ProMFG2026 #PMAMSummit #SmartMaintenance #ManufacturingExcellence #LeanManufacturing #PokaYoke #OEE #RootsGroup #ProcessOptimization

"Seventy-five percent of your product cost is locked in by materials, fixed overheads, and profits. Your entire operational survival hinges on how fiercely you optimize the remaining fifteen percent." - M. Vijayakumar, Head - Corporate Manufacturing Excellence & Manufacturing Engineering - Roots Group of Companies

June 2026 : When manufacturing leaders look at a product's cost structure, they quickly realize how little room they have to maneuver. Roughly 50% is tied up in raw materials set by global supply chains. Another 20% is absorbed by fixed management overheads and baseline profits, while another 10% goes to subcontracting and job orders. This leaves a narrow 15% under the direct control of the shop floor operations team. Because this small slice is highly vulnerable to human error, equipment downtime, and process variations, any small issue can completely wipe out a plant’s profitability.

This focus on operational precision anchored the panel at the 7th Edition of the Pro MFG Plant Maintenance & Asset Management (PMAM) Summit 2026 in Coimbatore. Hosted by Pro MFG Media alongside Presenting Partner - Mobil and Gold Partner - ImageGraphix, the summit focused on Achieving Maximum - Driving Productivity & Cost Efficiency Across Assets.

Taking the stage to outline how to defend that critical 15% margin was M. Vijayakumar, Head of Corporate Manufacturing Excellence & Manufacturing Engineering at Roots Group of Companies. Vijayakumar shared a practical, multi-tiered framework designed to eliminate waste and stabilize volatile manufacturing processes.

Vijayakumar broke down Roots' operational strategy into five systematic areas that target hidden losses and improve Overall Equipment Effectiveness (OEE):

1. 1. Capturing Low-Hanging Fruit: True process optimization begins with the person running the machine. By observing operator ergonomics and motion, the manufacturing engineering team can eliminate non-value-added activities (NVAs), often boosting productivity by 20% to 30% without adding expensive equipment.
2. 2. Low-Cost Mistake Proofing (Poka-Yoke): Productivity and quality must improve together. Roots integrates low-cost camera systems, interlocks, and mechanical sensors directly onto production lines to catch errors early. This setup finishes with automated, end-of-line product testing to guarantee defect-free shipments.
3. 3. Synchronized Material Flow: A perfect part loses its value if it gets stuck in transport. The facility focuses heavily on smooth material movement and complete lot traceability to lower Work-in-Progress (WIP) buffers and keep production moving.
4. 4. Process Assurance Systems: By utilizing digital Manufacturing Execution Systems (MES), Roots monitors production steps in real time, making sure actual operations match engineered cycle times perfectly.
5. 5. Targeted Automation Upgrades: When process data confirms a line is stable, the company invests in technology upgrades. For press-heavy setups, they use Single-Minute Exchange of Die (SMED) techniques to shorten changeover windows and tightly align cycle times with consumer demand.

When asked how to lower maintenance costs without hurting machine reliability, Vijayakumar highlighted the importance of changing the team culture. By introducing autonomous maintenance, Roots trains operators to handle daily cleaning, basic inspections, and lubrication checks themselves. This frontline care naturally extends asset lifespans. Meanwhile, specialized maintenance teams undergo continuous technical training on specific equipment. This combination of daily operator care and advanced predictive maintenance keeps precision tools running smoothly and protects the plant's core profitability.

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