Structure – Case Study

A trucking company faced constant downtime due to minor maintenance issues. A proactive inspection system increased fleet availability by 25%.

At least one of the company’s five trucks was always out of service due to small, preventable maintenance issues.
Minor problems like low fluids, worn tires, or overdue oil changes weren’t caught early.
Maintenance was reactive — trucks were only repaired after something went wrong.
Small issues often turned into larger problems because they weren’t addressed until they caused visible disruption.
Downtime reduced fleet capacity, limited revenue, and created constant scheduling headaches.
The company had five trucks but built operations around having only four available, expecting one to always be down.

At least one of the company’s five trucks was always out of service due to small, preventable maintenance issues.
Minor problems like low fluids, worn tires, or overdue oil changes weren’t caught early.
Maintenance was reactive — trucks were only repaired after something went wrong.
Small issues often turned into larger problems because they weren’t addressed until they caused visible disruption.
Downtime reduced fleet capacity, limited revenue, and created constant scheduling headaches.
The company had five trucks but built operations around having only four available, expecting one to always be down.

The problem wasn’t mechanical failure — it was the absence of a proactive maintenance structure.
No one was assigned to regularly inspect trucks before dispatch, so issues went unnoticed.
The company relied on drivers to report problems, but many issues were missed or delayed.
There was no process or checklist in place to ensure vehicles were road-ready each day.
Maintenance was treated as an afterthought, not a routine — which led to chronic, preventable downtime.

The problem wasn’t mechanical failure — it was the absence of a proactive maintenance structure.
No one was assigned to regularly inspect trucks before dispatch, so issues went unnoticed.
The company relied on drivers to report problems, but many issues were missed or delayed.
There was no process or checklist in place to ensure vehicles were road-ready each day.
Maintenance was treated as an afterthought, not a routine — which led to chronic, preventable downtime.

A structured, preventive maintenance routine scheduled before dispatch twice a week.
The yard manager should be responsible for early-morning truck inspections.
Small issues like fluid levels, tire wear, and minor repairs need to be identified and addressed immediately.
A standardized checklist should be used to ensure consistency and catch issues before trucks go out.
A tracking system is needed to monitor truck conditions and flag recurring maintenance patterns over time.

A structured, preventive maintenance routine scheduled before dispatch twice a week.
The yard manager should be responsible for early-morning truck inspections.
Small issues like fluid levels, tire wear, and minor repairs need to be identified and addressed immediately.
A standardized checklist should be used to ensure consistency and catch issues before trucks go out.
A tracking system is needed to monitor truck conditions and flag recurring maintenance patterns over time.

The yard manager adjusted their schedule to arrive at 3 a.m. twice a week, allowing inspections to take place before dispatch.
A standardized checklist was created and used during each inspection to ensure consistency.
Minor issues like low fluids, tire wear, or broken lights were addressed on the spot before drivers arrived.
The inspection system was communicated to the dispatch team and integrated into the weekly schedule.
A shared log was introduced to track recurring maintenance issues and create accountability.
The earlier shift suited the yard manager’s personal schedule, making the transition smooth and sustainable.

IMPLEMENTATION

The yard manager adjusted their schedule to arrive at 3 a.m. twice a week, allowing inspections to take place before dispatch.
A standardized checklist was created and used during each inspection to ensure consistency.
Minor issues like low fluids, tire wear, or broken lights were addressed on the spot before drivers arrived.
The inspection system was communicated to the dispatch team and integrated into the weekly schedule.
A shared log was introduced to track recurring maintenance issues and create accountability.
The earlier shift suited the yard manager’s personal schedule, making the transition smooth and sustainable.

Truck downtime was nearly eliminated — the company went from 4 available trucks to all 5.
Preventable issues like low fluids or tire wear were caught and fixed early, avoiding breakdowns.
Scheduling became smoother, and dispatch could rely on a full fleet each day.
The company saved money on emergency repairs and avoided lost revenue from unavailable trucks.
The owner regained peace of mind, knowing the fleet was being maintained systematically and reliably.

Truck downtime was nearly eliminated — the company went from 4 available trucks to all 5.
Preventable issues like low fluids or tire wear were caught and fixed early, avoiding breakdowns.
Scheduling became smoother, and dispatch could rely on a full fleet each day.
The company saved money on emergency repairs and avoided lost revenue from unavailable trucks.
The owner regained peace of mind, knowing the fleet was being maintained systematically and reliably.