UPS just completed a three-month reengineering of the preventive maintenance process for its 70,000 delivery vehicles. The results are - improved methods for mechanics, the reduction of oil usage and disposal by 330,000 quarts each year and savings of almost $3 million annually.
UPS's Automotive Study Group, an innovation "go team" in the company's Automotive Engineering Department, evaluated every aspect of the PMI process from oil changes and lubrication systems to warranty tracking. In addition, intensive time and motion studies were conducted to optimize each step a mechanic takes while performing the inspection.
The redesigned process is built around the individual characteristics of UPS's delivery fleet, essentially giving each vehicle its own fingerprint. Through rigorous part testing, real-time duty cycle analysis and fleet-wide assessments, the Study Group developed a detailed matrix of vehicle characteristics, including engine type, vehicle group, miles driven, days of service and manufactures' recommendations for oil changes and other types of engine service. It was this process, for example, that allowed UPS to better gauge how frequently a vehicle type needs an oil change. Some vehicles were found to need less frequent oil changes, providing the net savings of 330,000 quarts.
All vehicle characteristics are tracked by the company's proprietary Automotive Information System (AIS) software, a key factor in the success of UPS's maintenance programs. AIS tracks all aspects of fleet maintenance and notifies mechanics when a specific vehicle should come in for a preventive maintenance inspection. AIS removes the guesswork in planning labor for vehicle repairs, maintaining parts inventory and estimating fuel usage. The software also allows engineers to pinpoint trends and constantly refine methods and specifications.
