In today’s fast-paced manufacturing and forging industries, downtime isn’t just an inconvenience—it’s a major financial drain. Every hour of unplanned downtime means lost production, wasted labor costs, and potential damage to customer trust. The reality is, even the most advanced machinery is subject to wear and tear, and without a structured maintenance plan, small issues can rapidly escalate into costly failures. 

Many manufacturers adopt a reactive approach, addressing problems only after they arise. However, this approach comes at a steep price. Deloitte has conducted research on the impact of unplanned downtime in industrial manufacturing, highlighting that it can account for as much as 20% of overall productivity losses. Their study emphasizes how downtime-related inefficiencies go beyond just production halts, affecting overall operational costs, workforce efficiency, and long-term profitability.  

These costs go beyond immediate production halts—there are also ripple effects, such as missed customer deadlines, increased labor expenses for emergency repairs, and even reputational damage.  

Preventative maintenance is the key to mitigating these risks. By implementing a proactive strategy, businesses can extend equipment lifespan, optimize performance, and avoid costly disruptions. Ajax/CECO/Erie Press (ACE) is here to help you eliminate costly downtime and keep your operations running smoothly with a preventative maintenance program tailored to your specific needs. 

The Hidden Costs of Downtime 

Many businesses struggle with frequent, unexpected machine failures, leading to operational inefficiencies and financial losses. These breakdowns often stem from a lack of preventative maintenance planning and unavailable critical spare parts when they are needed most. 

The consequences of downtime extend beyond immediate production losses: 

• Frequent Equipment Downtime – Without regular maintenance, small issues quickly escalate into costly breakdowns, leading to unnecessary production stoppages. 

• Lost Revenue – When machines stop, production halts, leading to missed deadlines, frustrated customers, and potential lost contracts. Every minute counts in a competitive industry. 

• High Emergency Repair Costs – Emergency breakdowns demand immediate fixes, often requiring expedited shipping for replacement parts and overtime pay for repair crews. These reactive costs far exceed those of scheduled maintenance. 

• Reduced Efficiency – When equipment isn’t operating at peak performance, quality suffers. Defective parts, slower production speeds, and increased cycle times all contribute to inefficiencies that impact your bottom line. 

• Safety Risks – Unmaintained machinery presents significant safety hazards. Worn-out components, overheating systems, and sudden failures put employees at risk and can lead to costly regulatory penalties. 

Many businesses don’t realize that ACE offers tailored maintenance solutions to prevent failures before they happen. Without proactive servicing, companies are left scrambling when issues arise. 

How Much is Downtime Really Costing You? 

A recent analysis of downtime costs in manufacturing highlights just how financially devastating unexpected failures can be. In many cases, the cost of one hour of downtime far exceeds the investment in a preventative maintenance program. 

For a deeper dive into how strategic spare parts management reduces financial risk, check out our blog: The Financial Advantages of ACE’s Spare Parts Program. 

The solution? A proactive approach to maintenance. 

For more details, view our Preventative Maintenance Flyer here. 

Keep Your Machines Performing at Their Best with ACE’s Preventative Maintenance Program 

Why wait for a problem when you can prevent it? 

ACE’s Preventative Maintenance Program ensures your machinery remains in peak condition, reducing unplanned downtime and extending equipment lifespan. With regular inspections and proactive servicing by our expert technicians, you can catch potential issues before they escalate into costly failures. 

Key Features of ACE’s Preventative Maintenance Program: 

• Comprehensive Equipment Inspections: Our team conducts in-depth assessments to identify wear and tear, misalignments, and other potential failures before they occur. 

• Customized Maintenance Schedules: We work with you to develop a plan that aligns with your production cycle, minimizing disruptions. 

• Expert Repairs & Adjustments: Our technicians are highly trained in Ajax, Chambersburg, and Erie Press equipment, ensuring precise repairs and system optimizations. 

• Detailed Reporting & Recommendations: Every maintenance visit includes a full evaluation, allowing you to make data-driven decisions for equipment longevity. 

The Benefits of ACE’s Preventative Maintenance: 

• Minimized Downtime: Identify and address issues before they cause machine failures. 

• Extended Equipment Life: Routine servicing helps your machinery operate efficiently for years to come. 

• Optimized Performance: Well-maintained machines produce higher-quality parts with greater consistency. 

• Cost Savings: Avoid emergency repairs and lost production time with proactive maintenance. 

• Improved Workplace Safety: Reduced machine failures mean fewer workplace accidents and compliance violations. 

Keep your machines performing at their best with ACE’s expert preventative maintenance. 

Ready to take control of your equipment’s reliability? 

Sign Up for Preventative Maintenance Today! 

Avoid Downtime with a Tailored Parts Stocking Solution from ACE 

One of the biggest contributors to extended downtime is waiting for the right part. Without a stocked inventory, a simple component failure can grind operations to a halt, creating production bottlenecks and unexpected costs. 

Why ACE’s Parts Stocking Program Is Essential 

• Eliminate Delays: A machine failure shouldn’t put your entire operation on hold. With ACE’s stocking program, you’ll have immediate access to critical parts. 

• Reduce Costs: Instead of rush ordering expensive components, maintain a strategic inventory of essential spare parts, keeping costs predictable. 

• Ensure Uninterrupted Production: Keep your machines running by having replacement parts on hand before you need them. 

The Advantages of ACE’s Parts Stocking Program: 

• Reduced Lead Times: No more waiting weeks for critical components. 

• Increased Productivity: Your machines stay running without extended delays. 

• Peace of Mind: Be prepared for unexpected repairs with a stocked inventory of essential parts. 

• Tailored Stocking Plans: We customize stocking solutions based on your machine usage, ensuring efficiency without excessive overstocking. 

Avoid downtime with a tailored parts stocking solution from ACE. 

Ensure Your Operations Run Smoothly—Request a Health Check 

Partner with ACE for a Reliable, Profitable Future 

Downtime doesn’t have to be an inevitable cost of doing business. By investing in ACE’s Preventative Maintenance & Parts Stocking Program, you’re taking a proactive step toward greater efficiency, reliability, and profitability. 

Why Choose ACE? 

• Decades of Industry Expertise: Our skilled technicians understand the unique needs of forging and manufacturing businesses. 

• Reliable Service & Support: Our programs are designed to deliver consistent, dependable maintenance and stocking solutions. 

• Cost-Effective Maintenance Plans: We work with you to develop solutions that fit your operational and financial goals. 

Take Action Today 

Keep Your Operations Running Smoothly—Request a Health Check 

Don’t wait until downtime costs you thousands. Stay ahead of the curve with ACE. 

Visit ajaxerie.com to learn more about how ACE can help your business thrive.