Industrial ConstructionQuality Installations
Case Study: Rapid Coil Cart Replacement GetsProduction Back Online
Problem
A coil slitting manufacturer experienced a sudden failure of a critical coil cart, bringing production to a
complete stop. Without the cart in operation, material flow through the line was halted, preventing
continued processing. Each hour of downtime increased pressure on production schedules, workforce
utilization, and customer commitments. The facility needed immediate support to supplement its
internal maintenance team with experienced rigging and millwright resources capable of executing a
complex equipment changeout under tight time constraints—while coordinating with electrical and
controls personnel to ensure a complete restart.
Solution
FABCO responded quickly by providing skilled rigging specialists and millwrights to augment the
customer’s internal team. Working collaboratively, FABCO supported the removal of the failed coil cart
and the installation of the replacement unit. By integrating seamlessly with the customer’s personnel as
well as electrical and controls resources, the combined team was able to execute multiple workstreams
in parallel. This included mechanical changeout, electrical tie-ins, and controls integration occurring
simultaneously rather than sequentially—significantly reducing total downtime. FABCO’s crew
contributed critical expertise in precision setting, alignment, and mechanical installation, helping ensure
the new coil cart was installed safely, accurately, and ready for startup.
Result
Within just 10 hours, the replacement coil cart was fully installed, integrated, and operational. The
production line was successfully restarted in time for second shift, greatly reducing the operational
impact of the failure. By supplementing the customer’s internal workforce with experienced rigging and
millwright support, FABCO played a key role in accelerating the recovery and minimizing lost
production time.
Key Outcomes
-Coil slitting line restored in 10 hours
-Production resumed for second shift
-Downtime significantly minimized
-FABCO provided supplemental rigging and millwright expertise
-Strong collaboration with customer and trades
-Accelerated return to full production operations
Case Study: Packaging Line Replacement
Problem
A prominent brewing corporation required the simultaneous replacement of 2 canned
beverage packaging lines while keeping their production running, and minimal impact
on their other operations.
Solution
FABCO was able to mobilize with crews of millwrights and pipefitters working around
the clock in close collaboration with our sister company ABCO South Electric to
accomplish this task. We removed and replaced their conveyance systems, twin-stack
packers, shrink wrappers, labelers, and process utility piping from the can filler to the
palletizers in just a few short weeks. We were able to integrate these upgrades in a way
that minimized their downtime and kept their production flowing.
Result
Within a few short weeks, both packaging lines were fully upgraded, finished with
commissioning, and began production, producing a higher output than expected.
Key Outcomes
-Production on both lines resumed in a few short weeks
-Downtime was minimized during replacement
-Customer had a higher-than-expected output once completed."
— FABCO Industrial Construction LLC · Delivering Quality Installations
© Copyright 2015 FABCO LLC. All rights reserved.