21%
Increase in electrician productive time
Enhancing Electrician Productivity to Balance Maintenance and Capital Demands: Boosting Maintenance Efficiency While Supporting Critical Capital Projects
Industry: Transportation, Logistics and Services
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A major metropolitan rail agency facing a growing State of Good Repair backlog due to electrician reassignment to capital projects and insufficient preventive maintenance execution.
The Challenge
Key operational issues limited maintenance performance and labor efficiency:
- Electricians frequently reassigned to capital projects, leaving preventive maintenance tasks unfinished.
- Preventive maintenance inspections falling behind schedule.
- Growing SGR backlog due to reduced inspection capacity.
- Lack of structured planning tools and visibility into labor productivity.
Real Results Achieved Together
Through structured planning, standardization, and daily performance management, EFESO helped the Electric Division increase productive labor time, achieve preventive maintenance targets, and restore balance between capital projects and maintenance operations.
>95%
Preventive maintenance schedule attainment for DC and Bonders crews (up from 44%)
Transformation Impact
- Rebalanced labor allocation between capital projects and maintenance operations.
- Reduced backlog growth and improved State of Good Repair compliance.
- Established daily Pulse meetings and digital planning tools to reinforce execution discipline.
- Standardized maintenance task timing to maximize productive work per shift.
Our Approach
EFESO applied a multi-faceted strategy combining planning, standardization, and performance management.
Daily Visual Planning & Scheduling
- Implemented a 7-day lookahead plan with daily Pulse meetings.
- Deployed digital scheduling boards for real-time visibility of preventive maintenance work.
Standardization of Preventive Maintenance
- Conducted field studies to define realistic time standards for maintenance tasks.
- Applied the “Fill the 480” methodology to ensure full productive work per shift.
Daily Performance Management
- Reinforced schedule adherence and accountability through Pulse meetings.
- Introduced transparent productivity metrics to support data-driven decision-making.
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Facing Similar Challenges?
- Electricians or technicians frequently pulled from preventive maintenance to support projects.
- Growing backlog or overdue inspections.
- Increase labor productivity while balancing maintenance and capital priorities.
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