Apex Tool Works saved $1.6M in downtime by moving from reactive firefighting to scheduled maintenance
A tool & die manufacturer with 200+ pieces of equipment had no asset register and no maintenance plan — every breakdown was a surprise costing $40K an hour. Asset tracking with QR-coded maintenance schedules flipped them to proactive.
This is an illustrative case study. Company names, identifying details, and testimonials have been changed to protect client confidentiality. The technical solution and target outcomes are representative of the work we do. We extend the same confidentiality to every client.
Where they started
Apex's 200+ machines, presses, and hand tools were tracked in a binder that nobody updated. When a 1980s stamping press went down, the maintenance team would spend hours just figuring out which spare part fit which machine. Breakdowns cost an estimated $40K per hour in lost production, and the team was replacing equipment that, with proper maintenance, had years of life left.
What we built
We deployed our Asset Tracker platform with QR codes on every asset, a complete digital register tied to manuals and spare-part lists, scheduled maintenance workflows that trigger automatically based on runtime hours, and floor-plan visualizations showing every asset's status. Operators scan to report issues; maintenance gets a prioritized queue.
Target outcomes
More from this project
We used to lose half a shift finding the right manual and the right spare part. Now a technician scans the QR code and has everything in front of them before they pick up a wrench. The downtime savings paid for the platform three times over.
Representative testimonial — name and role changed to protect client identity.