Skip to content
01  /  Headquarters — Birmingham, AL
01 / Case Study Archive

An audited archive of reliability engagements, 2018–2024.

Six programs, five sectors, one measurement standard. Every figure below was audited independently by the client’s own finance team. Most engagements are protected by NDA — what you can read here is what the client’s CFO signed off on.

Book a Reliability Diagnostic Read the Engagements ↓
612 industrial sites served since 2007
47 Fortune 1000 manufacturers on retainer
98% client retention across multi-year programs
41 U.S. states, 9 countries
Baseline scoring MDG Reliability Maturity Index — 7 dimensions, 0–100
Financial audit Client-side finance team, DNV oversight on ISO 55000 alignment
Reporting window 12-month baseline → 12-month re-score, 18-month ROI close
02 / Engagements by Industry

Six programs, five sectors, one measurement standard.

Each card reports a single engagement with the same four KPIs: OEE lift, unplanned downtime reduction, ROI multiple, and the program length required to deliver it. Numbers are anonymized engagements drawn from the 47 Fortune 1000 programs in our active archive.

CS-01 · Cross-industry flagship

Managed Reliability Program, 14-site North American platform

Fortune 100 food & beverage manufacturer · Midwest U.S. · 14 plants, 9,200 employees

Thirty-six month engagement covering two bakeries, three beverage lines, four protein facilities, and five ingredient plants. Program built around a centralized reliability operations center, condition-based maintenance on critical rotating equipment, and standardized root-cause analysis across all 14 sites.

  • Senior principal engineer on-site monthly; remote reliability analysts staffed continuously
  • MDG Reliability Maturity Index baseline re-scored at every quarter
  • Cap-ex reallocation plan reviewed jointly with client CFO each fiscal year
OEE lift+11.6 pts
Unplanned downtime−52%
Audited ROI6.1× · 17 mo. payback
Maturity Index38 → 71
Program length36 months
CS-02 · Food & Beverage

Dairy processing facility, U.S. Southeast

Private-label fluid milk and yogurt · 1 plant, 6 packaging lines

OEE lift+9.4 pts
Unplanned downtime−46%
Audited ROI5.2× · 14 mo.
Maturity Index34 → 64

Focus: hygienic-area asset care, CIP loop reliability, and sanitation-to-startup time loss analysis. Direct-fired ammonia refrigeration redesign reduced nuisance trips by 81%.

CS-03 · Pharmaceutical

Sterile injectable manufacturing campus

Top-10 pharma manufacturer · U.S. Northeast · 2 buildings, GMP-regulated

OEE lift+8.2 pts
Unplanned downtime−58%
Audited ROI4.7× · 19 mo.
Maturity Index41 → 73

Focus: cleanroom-grade preventive maintenance, validated change control on calibrated instruments, and qualification-ready documentation for FDA inspection cycles.

CS-04 · Pulp & Paper

Containerboard mill, U.S. South

Integrated paper manufacturer · 1 mill, 2 lines, 1,400 employees

OEE lift+13.1 pts
Unplanned downtime−61%
Audited ROI7.4× · 12 mo.
Maturity Index29 → 68

Focus: dryer-section vibration analysis, sectional drive reliability, and recovery-boiler inspection interval optimization. Annual outage duration reduced by 6.3 days.

CS-05 · Petrochemical

Ethylene cracker turnaround, U.S. Gulf Coast

Global petrochemical operator · 1 facility, 1.2M-ton annual capacity

OEE lift+7.8 pts
Unplanned downtime−49%
Audited ROI5.5× · 16 mo.
Maturity Index46 → 70

Focus: rotating equipment (compressors, turbines), PSM-aligned critical-task analysis, and risk-based inspection program rebuild for fixed equipment.

CS-06 · Utilities

Combined-cycle power plant, 1,200 MW

Investor-owned utility · U.S. Mid-Atlantic · 2 units, 2 gas turbines each

OEE lift+10.2 pts
Unplanned downtime−44%
Audited ROI4.9× · 18 mo.
Maturity Index37 → 66

Focus: gas turbine reliability-centered maintenance, balance-of-plant pump monitoring, and NERC-aligned spare-parts criticality modeling.

03 / Consolidated Outcomes

Across 612 engagements, 2018–2024.

Averages below are drawn from 47 named Fortune 1000 programs and audited independently by client finance teams.

8–14pts OEE lift range, 12-month program MDG Reliability Maturity Index baseline vs. 12-month re-score
40–60% Unplanned downtime reduction Compared to trailing 12-month baseline pre-engagement
14–18mo. Average payback period Audited finance teams, period-by-period reconciliation
5.8× Average audited ROI 18-month close, exclusive of soft-cost categories
04 / Methodology

How these numbers were measured.

Every figure published in this archive is sourced from the client’s own finance close — not from MDG projections. The protocol below is the same one used by the 47 named Fortune 1000 programs in the active archive.

OEE lift

Calculated as the change in 12-month rolling OEE between the pre-engagement baseline and the 12-month re-score window. Both endpoints are taken from the client’s MES or historian data, not from MDG’s own modeling. The headline figure reflects availability × performance × quality, identical to the SEB-defined OEE.

Unplanned downtime

Reported as the percentage reduction in unscheduled hours between baseline and re-score windows. Excludes planned outages, force majeure, and customer-driven schedule changes. Volatile weather events are normalized using the client’s own weather-day methodology.

Audited ROI

ROI is calculated on hard-cost savings only: labor productivity, parts spend reduction, overtime, and avoided production loss. Each engagement is reconciled by the client’s own finance team against their general ledger. MDG does not include projected savings, modeled soft-cost gains, or platform-attributed improvements.

MDG Reliability Maturity Index

Seven-dimension assessment covering strategy, work identification, work execution, asset performance, materials, workforce capability, and continuous improvement. Each dimension is scored 0–100 against ISO 55000-aligned criteria. The same instrument is used across all 600+ North American plants in the benchmark set.

What is not included

No platform-tied figures, no AI-derived projections, no synergies from software the client has not yet purchased, no modeled outcomes beyond the 18-month close window. Where ISO 55000 alignment is cited, the methodology is audited annually by DNV.

NDA compliance

All named Fortune 1000 clients operate under NDA. The cards above are anonymized but representative — the underlying data tables are made available to qualified buyers during the Reliability Diagnostic, with client consent, under a one-way data-sharing agreement.

“MDG was the first firm that did not try to sell us a platform. Their senior engineers were on the floor every month, and the ROI number was signed by my CFO, not their marketing team. Twelve months in, we were the benchmark site for the rest of our network.”

Director of Reliability Fortune 500 food & beverage manufacturer · Midwest U.S. Engagement CS-01, year-two close
06 / Next Step

Bring your baseline. Leave with a 90-day reliability roadmap.

A 30-minute Reliability Diagnostic with a senior principal engineer. Bring your trailing 12-month OEE, your current work-order backlog, and one or two of your hardest asset-care problems. You will leave with a prioritized 90-day plan and an MDG Reliability Maturity Index score you can take to your leadership team.

  • 30-minute call, no slides, no sales pitches
  • Senior principal engineer on the line — not an analyst, not a BDR
  • Optional NDA & one-way data-sharing if you want case-study benchmarks
Book a Reliability Diagnostic Review the Service Methodology

Maintained in Birmingham, Alabama, since 2007. ISO 9001:2015 certified since 2014; ISO 55000-aligned methodology audited annually by DNV.