Case Study: Manufacturer Prevents Downtime with Condition Monitoring

Even brief periods of downtime for an automotive manufacturer can translate into significant production losses and costly effects across the supply chain. Many manufacturers face the challenge of keeping increasingly complex equipment running at peak performance while operating with limited internal technical resources. To address this, manufacturers are turning to condition monitoring technologies that provide real-time visibility into equipment health, allowing them to predict and prevent failures before they disrupt production. This case study explores how one field services team partnered with a major automotive manufacturer to design, install, and scale a condition monitoring system that not only improved uptime but also delivered measurable financial impact across multiple facilities. 

Problem 

The automotive manufacturer was seeking to improve equipment reliability and reduce costly downtime in their production facility. Their internal team recognized the need for a robust condition monitoring solution but faced a critical challenge: 

• Limited technical resources to handle the installation and setup of a large-scale system.
• Urgent need for an experienced partner capable of both deploying the technology and training their maintenance staff to use it effectively.
• Vendor comparison revealed that while other suppliers could provide the product, they lacked the ability to execute a complete turnkey installation. 

The manufacturer required a partner who not only understood the technology but could also deliver full integration support—ensuring the system was properly deployed and that their in-house team could sustain it long-term. 

Solution 

The customer selected GCG Automation & Factory Solutions’ field services team over a competing distributor because of our ability to manage the installation end-to-end. The project’s goal was clear: deploy a system to monitor equipment health in real time and proactively prevent unplanned downtime. 

Services Provided

• Condition Monitoring Deployment
  • Installed a Banner Engineering condition monitoring system with hundreds of sensors across critical production assets.
  • Sensors to track vibration, temperature, and performance metrics.
• Training & Knowledge Transfer
  • Conducted hands-on training sessions with the customer’s maintenance staff, ensuring they could install, program, and expand the system themselves.
• Collaborative Execution
  • Internal team members Kevin McFarland, Tom Carpenter, Yancy, and Joel Braun led the project alongside the Banner Engineering team.
  • Partnered with a subcontractor to support specialized installation tasks. 

Results 

The project delivered measurable improvements and long-term value for the customer: 

• Operational Reliability - Real-time monitoring significantly reduced the risk of unplanned downtime by detecting issues before failures occurred. 
• Scalable Success - The successful pilot led to expansion of the solution across multiple Toyota facilities, multiplying the operational benefits. 
• Financial Impact - Customer recognized a rapid ROI through improved uptime and reduced maintenance costs. 
• Customer Confidence - Feedback emphasized the value of having a partner who could not only deliver the product but also provide the technical services and training to make the system sustainable. 

Conclusion 

This customer case study demonstrates the value of GCG Automation & Factory Solutions’ field service team as a true extension of our customers’ engineering resources. By bridging the gap between product supply and full system deployment, GCG helped an automotive manufacturer achieve: 

• Faster implementation of advanced technology
• Immediate operational improvements
• Scalable results across multiple facilities 

For manufacturers with limited in-house technical staff, this approach provides a repeatable, proven model to achieve reliability and uptime goals without overextending internal resources. 

At GCG Automation & Factory Solutions, our technical services team helps customers keep operations running and reduce down time. As a total service solutions provider we simplify the support process for manufacturers by offering a single source for both products and services.