Case study · Irving, Texas

Brakebush Brothers, Irving: from finger-pointing to 90%+ on-time starts

Plant Manager Hermelando Sanchez on one shared goal for maintenance and operations.

Brakebush Brothers · Irving, TX 90%+

From finger-pointing to 90%+ on-time starts.

Up from under the plant's 80% goal, and holding week to week.

Hermelando Sanchez, Plant Manager, Brakebush Irving, on working with Steve Baumgartner and Fire Forged Enterprise.

Problem: On-time line starts at this two-plant site were running under the plant's 80% goal. Maintenance and operations blamed each other for startup misses, and about 2 hours a week were lost to startup problems.
Cost: Labor sat idle at every late start, capacity was stuck, and the two departments were working against each other.
Action: Built a cross-functional team of maintenance and operations, led by third-shift leader Billy McDonald, using the Fire Forged method. The team met regularly, set one shared goal, owned startups together, and followed the same process every day.
Result: On-time starts now run consistently in the 90s, week to week. Labor savings are $7,252 per period across all lines, about $87K per year, and more line capacity is now open.

“It doesn't help our leaders to grow in pointing fingers.”
Hermelando Sanchez, Plant Manager, Brakebush Irving

Tell me what's happening on your floor. I'll tell you whether it's worth a closer look, and where I'd start.