Enhancing Maintenance Productivity with Data-Driven Performance Standards

Client Context

A major metropolitan transit agency was struggling with low technician productivity and weak frontline performance management in its bus maintenance operations. In response, leadership requested the development of a centralized Power BI dashboard to provide real-time visibility into daily maintenance productivity across three facilities.

Key Challenges

• Frontline supervisors were not effectively driving daily technician performance.

• Maintenance planners were assigning only 50% of the available workload.

• Technician efficiency and productivity were well below expected standards.

• Lack of standardized performance metrics and tools to track effectiveness.

Approach & Key Success Factors

EFESO implemented a structured diagnostic and improvement approach:

• Operational & Data Analysis: Conducted a performance review to identify key inefficiencies.

• On-site Interviews & Process Observations: Validated initial findings through field visits and Industrial Engineering techniques.

• Gap Analysis: Benchmarked current performance against internal targets and external best practices to identify improvement potential.

• Execution Roadmap: Designed a phased improvement plan including prioritized initiatives, timelines, resourcing, and expected ROI.

• Performance Standards Dashboard: Developed a Power BI tool to monitor technician workload, task efficiency, and daily productivity.

Results

65-73%

Technician efficiency observed on direct tasks

40-65%

Range of daily direct work actually performed by technicians

28%

Labor productivity improvement identified

$8-10M

Direct Labor Costs

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