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SMART Maintenance.
Safe Workplace.
Real Results on the Shop Floor.
About Us
The professionals at Manufacturing Solutions provide a range of technical support services to clients that integrate workplace safety and health in conjunction with maintenance excellence focused on protecting employees, reduce equipment downtime, and improving overall equipment effectiveness. The company seeks to become true members of our clients’ team working with all employees, from the C-Suite to the shop floor, to gain comprehensive insight into daily operations. This insight translates to customized solutions meeting our clients’ needs.
Maintenance excellence services aim to improve both the skills and knowledge of maintenance professionals through shop-floor workshops, as well as focusing on equipment operation and functionality to strengthen equipment reliability, process stability, and overall operational performance. The professionals guide organizations to develop clear standards, risk-based maintenance schedules, and actionable go/no-go criteria so teams can prevent failures instead of reacting to them.
Safety and health services focus on workplace and equipment studies, worker interviews and education programs, and site-specific program and procedure development. The professionals guide organizations to optimize the organizational and operational factors that influence the worker and management decision-making process to achieve operational excellence.
Regulatory compliance services provide technical support in traditional topics including chemical hazard communication, confined space programs, emergency response, and assessments of noise and chemical exposure. Manufacturing Solutions is uniquely qualified in the specialty areas of machine safeguarding design and installation, electrical safe work practices, and laboratory safety.
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Services
Preventive Maintenance Programs
What We Did
- Performed an asset criticality analysis
- Developed equipment-specific PM procedures
- Educated employees across multiple facilities
- Standardized PM schedules
Results
- Increased equipment uptime and overall equipment effectiveness (OEE) through improved throughput, availability, and quality
- Enhanced product quality and consistency
- Scaled and replicated best practices across multiple facilities
- Elevated workforce capability through targeted skill development
- Implemented standardized preventative maintenance processes for consistency and reliability
Predictive Maintenance Programs
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What We Did
- Educated maintenance technicians on ultrasound and infrared technologies
- Identified early-stage equipment deterioration before downtime occurred
- Applied Predictive (PdM) tools to reduce energy losses
- Used condition monitoring and analytics to increase machine availability
Results
- Prevented unplanned downtime by 50%
- Lowered costs by reducing energy waste
- Increased overall equipment reliability
- Improved planning accuracy
Total Productive Maintenance (TPM)
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What We Did
- Formalized and implemented operator-led maintenance practices
- Implemented 5S and workplace organization to reduce waste
- Integrated predictive and lubrication programs
Results
- Improved uptime
- Reduced operating costs
- Strengthened competitive position
- Overall enhancement to the safety culture
Asset Management & Reliability
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What We Did
- Implemented Reliability Centered Maintenance (RCM)
- Identified high-risk failure modes and overall impacts
- Defined and executed targeted countermeasures to prevent failures
Results
- Prevented major disruptions during plant expansion
- Maintained uptime for critical systems
- Avoided costly impacts to infrastructure expansion
Continuous Improvement
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What We Did
- Implemented continuous improvement framework tailored to maintenance
- Facilitated hands-on focused improvement kaizen events
- Documented best practices with training guides
- Developed repeatable processes to sustain high performance
Results
- Performance gains achieved across multiple sites
- Factory throughput increased improving the bottom line
- Elevated workforce engagement and internal process for transferring knowledge
- Sustainable culture of improvement established
Maintenance Excellence
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What We Did
- Total productive maintenance and predictive maintenance protocols
- Optimization of the computerized maintenance management system
- Maintenance planning & scheduling standard operating procedures
- Targeted maintenance skills assessments and structured training programs to strengthen workforce capabilities
Results
- Substantially increased equipment uptime and reliability by 20%
- Reduced maintenance cost per case to the lowest level across all company plants
- Improved maintenance efficiency though structured planning and training
- Established a proactive, reliability-driven maintenance culture across the organization
Machine Safeguarding
What We Did
- Performed equipment assessments at multiple sites across the country
- Identified standardized safeguarding across common equipment
- Created concise documentation packages for each abatement to support compliance, audits, and ongoing safety management
- Designed cost-effective, compliant safeguarding solutions to each machine, balancing safety requirements with operational efficiency and budget constraints
Results
- Lowered the risk of incidents, injuries, and associated regulatory exposure by 20%
- Created a standard for consistent safety practices across multiple plants
- Increased Overall Equipment Effectiveness (OEE) with safer, more reliable machine operations that increased uptime, improved performance and fewer defects
Energy Control Procedures (LOTO)
What We Did
- Established a standardized picture-based energy control procedures form.
- Standardized equipment leading to one procedure for “like equipment”
- Worked with maintenance staff to formalize and validate each procedure, conduct effective employee training, standardization of spare parts inventory across organization
Results
- Significantly reduced exposure to hazardous energy incidents through clear, visual procedures that employees can easily follow
- Increased compliance with OSHA LOTO requirements
- Reinforced safe behaviors and strengthened overall safety culture
- Reduced spare parts inventory and associated costs
Electrical Safety (NFPA 70E)
What We Did
- Performed arc flash risk assessments across multiple facilities
- Standardized electrical safety programs to ensure consistency and compliance
- Provide support for equipment labeling and technical documentation
- Delivered training for qualified electrical workers
Results
- Identified critical hazards and reduced electrical risk exposure by up to 40-60%
- Achieved 100% alignment with NFPA 70E labeling and documentation requirements
- Increased employee knowledge retention and reduced unsafe behaviors
Industrial Hygiene & Air Quality
What We Did
- Researched chemical information to determine chemical characteristics
- Performed airborne chemical monitoring and sampling
- Identified alternative chemicals with same cleaning properties with less hazardous chemical
- Established glove specification and selection
- Industrial hygiene and employee education program development
Results
- Eliminated hazardous chemicals within process
- Selected alternative chemicals based on product
- Reduced airborne chemical exposure levels by >50%
- Implemented local ventilation to reduce airborne containment levels
- Created standardized work methods and reduced chemical usage and waste generation
Regulatory Resolution Support
What We Did
- Respond to regulatory inspection
- Acted as a technical expert on behalf of company
- Identified and resolved compliance gaps
- Reviewed and negotiated citations
- Developed short and long-term corrective action plan
- Strengthened internal compliance processes
Results
- Faster resolution of regulatory citations and enforcement activities
- Reduced penalties and operational disruptions
- Improved audit readiness and documented compliance processes
- Stronger relationships with regulatory agencies and stakeholders
Lean & Safety Integration
What We Did
- Eliminate operational waste without compromising worker well-being
- Incorporate safe work practices into daily workflows and process design
- Align frontline employees, leadership, and systems around shared safety and efficiency goals
- Drive sustainable performance through a unified approach to operational excellence and safety
Results
- Increased productivity without increasing risk exposure
- Fewer incidents due to proactive hazard elimination
- More engaged teams aligned around safety and performance goals
- Sustainable operational improvements with built-in safety controls
Safety Programs & Employee Training
What We Did
- Design and deliver customized safety programs aligned to your specific risks and operations
- Tailor content to your workforce, industry requirements, and regulatory environment
- Combine practical instruction with real-world application for immediate impact
- Drive lasting behavior change that improves safety performance across the organization
Results
- Increased employee awareness and accountability for safety
- Reduced incident rates and workers’ compensation costs
- Stronger safety culture across all levels of the organization
- Measurable improvements in compliance and performance metrics
Practical maintenance systems that work in real factories.
We don’t deliver binders. We deliver operating systems for your equipment. Our approach helps organizations:
Preventive Maintenance Programs
Increase equipment uptime and reliability
Improve process stability and product quality
Strengthen safety and regulatory compliance
Build internal ownership of maintenance practices
The result isn’t short-term gains. It’s sustainable performance.
CONTACT US
Preventive and Predictive Maintenance — The SMART Way
A SMART maintenance program:
Guide environmental compliance and promotes workplace safety
Reduces unplanned failures and increases overall equipment uptime
Balances predictive maintenance that can be done during operation with go / no-go criteria
Is scheduled at appropriate, risk-based intervals
Aligns with actual failure modes, not just OEM recommendations
Educates technicians on normal vs. abnormal equipment behavior
Preventive and Predictive Maintenance — The SMART Way
Safety
Properly maintained equipment operates more safely and consistently. SMART maintenance reduces risk exposure and improves workforce health.
Money
Preventive and predictive maintenance reduces failures, lowers repair costs, and improves production throughput.
Asset Longevity
Structured maintenance programs extend equipment lifespan and improve long-term asset value.
LEARN MORE ABOUT OUR TRAINING
Built for execution. Designed for ownership.
Our goal is not dependency. It’s Empowerment.
Assess & Identify
We perform thorough maintenance and safety assessments to identify operational risks, failure modes, and performance gaps.
Plan & Execute
We develop SMART preventive and predictive maintenance programs tailored to your equipment, environment, and workforce.
Educate, Improve & Sustain
We train your team to follow best practices and hand over full program ownership to ensure long-term success.
Experienced practitioners. Not career consultants.
Partner Firms
Let’s talk about your operation.
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Manufacturing Solutions by Fuss & O’Neill
Hands-on training.
SMART maintenance. Measurable results.
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