Elevating Technical Expertise in an Automotive Manufacturer

Client

A leading car maker known for strong design and efficient plants was losinguptime and money. Technician skills in advanced maintenance and safety lagged.Morale was slipping.

Challenge

A clear skill gap in core maintenance practices and safety hurt output, raisedcosts, and increased risk.

Approach

Jeruel designed a practical program aligned to the SMRP 5 Pillars. We focusedon hands-on skills, clear safety habits, and daily application. Each topicended with an exercise or assessment so learning stuck.

Training program

1. Maintenance practices
   ‍
   
   • Safety deep dive covering bloodborne pathogens, confined space, electrical safety, emergency response, environmental rules, and ergonomics.
   • Strong basics on lockout/tagout, PPE, and machine safety systems.
   • Interactive drills and case reviews to test understanding.
     ‍
2. Preventive and predictive maintenance.
   ‍
   • Practice with PM setup and scheduling.
   • PDM methods using vibration checks, infrared thermography, and oil analysis.
   • Equipment specifics on lubrication systems and alignment for rotating assets.
 
3. Troubleshooting and analysis
   ‍
   
   • Structured problem solving that starts with facts, verifies the fault, and uses the right documents.
   • Smart use of CMMS and technical libraries to spot patterns and speed fixes.
   • Step-by-step elimination to reach root causes.
     ‍
4. Corrective maintenance
   ‍
   • Tear-down, inspect, repair, and reassemble using best practice.
   • Post-repair monitoring to confirm the fix.
   • Simulations and real-world scenarios to build confidence.

Implementation

Delivery ran in phases to avoid disrupting production. Each phase combined short theory blocks, guided practice, and quick checks for progress.

Results

• Uptime became steadier and more predictable without adding new capital.
• Turnover eased, and technicians reported higher confidence and satisfaction.
• Safety behaviors improved, with stronger compliance and fewer near misses.
• Teams built habits and skills that continue to pay off as technology changes.

Bottom line

Sharper skills, safer work, and steadier production.