faces of the frontline: manufacturing’s all stars

José Peralta didn’t set out to become a maintenance superstar. In fact, when he started three years ago at Olli Salumeria in Oceanside, California, he’d never worked in maintenance before. But it didn’t take long before José was ready to move beyond his initial position as a setup technician and move up the ladder to his role as Preventative Maintenance (PM) technician. Since then, he’s helped usher in big changes that led to reductions in downtime and a facility-wide commitment to continuous improvement.

Preventative Maintenance With a Big Impact

José’s military service instilled an attention to detail. This, along with a curiosity about how the machines worked and a desire to learn more, made him shine as a setup technician. He immediately went beyond simply setting up machines to taking them apart and putting them back together. Then, when something wasn’t right, he would replace worn parts without being told. It was a no-brainer that he was quickly promoted to the PM Technician role. “We didn’t have any doubts because he was pretty much doing that from the beginning,” says Raphael Corea, Maintenance Manager.

José’s willingness to train others on these complex tasks has not only improved the team’s technical skills but also fostered a sense of camaraderie and mutual support. An example is when José learned to disassemble and replace cutters on the MULTIVAC machines. The MULTIVACs require regular maintenance, from changing out the knives to taking them apart for monthly deep cleaning and reassembling them. If one of these machines goes down, it delays the entire line. 

To keep the MULTIVACs running, José learned how to disassemble and clean the machines and replace the cutters. He also developed a cleaning and cutter replacement schedule. Finally, he trained the team on how to perform the maintenance. “Just from changing the slitter knives and making sure there’s no trim in the MULTIVAC, that’s decreased (downtime) tremendously,” says Robert McNew, Director of Operations.

José understands that the nature of continuous improvements is that there’s always more to be done. That’s why he’s worked hard to help usher in a cultural shift toward preventative maintenance at Olli Salumeria. Previously, the team operated in a reactive mode—constantly putting out fires as issues arose. Through José’s implementation of preventative measures and regular maintenance routines, the team has drastically reduced unplanned downtime and freed up managers to work on other projects. 

Discipline and Problem-Solving

Though José had no maintenance experience before Olli Salumeria, he had another valuable skill: a rigorous discipline he learned in the U.S. Marine Corps. This Marine veteran’s meticulous approach to maintenance and problem-solving has played a pivotal role in reducing downtime on the labelers. 

When he was initially tasked with cleaning the labelers, José quickly expanded his responsibilities to include thorough inspections and repairs as well. “In the Marine Corps, they teach us to leave things as good or better than you find them,” says José. After those repairs, he developed a comprehensive checklist to identify and address potential issues such as broken belts, missing hardware, and damaged air hoses. 

Creating the detailed checklist for labeler inspections is a prime example of José’s talent for simplifying complex processes and making them accessible so anyone on the team can spot and fix problems. The labeler checklist has streamlined tasks, reduced downtime, and empowered his team to address issues proactively. It’s become a vital tool for the team, simplifying the maintenance process and ensuring consistent operational efficiency.

José’s keen eye for detail and systematic approach didn’t stop there. He’s also trained others, sharing his knowledge to ensure long-term reliability. His efforts in maintaining and improving the labelers have significantly reduced disruptions and decreased downtime. This, in turn, increased throughput from 50% to an impressive 65%.

“Helpful, Informative, and a Great Guy”

José’s success at Olli Salumeria is as much a testament to his communication and interpersonal skills as it is to his technical expertise. He never seeks out attention himself, preferring to direct his energy toward helping his team and sharing knowledge. José’s efforts to mentor others are evident in his hands-on training sessions, where he patiently guides his teammates through intricate tasks such as disassembling and replacing cutters on the MULTIVACs. 

José has also improved the flow of information at Olli Salumeria by conducting regular “doctor’s rounds” and documenting detailed notes of his findings in Redzone. This helps keep everyone informed about the status of the equipment and reduces the need for reactive problem-solving.

Both management and José’s colleagues on the floor speak highly of his impact, describing him as „helpful,“ „informative,“ and „a great guy all around.“ José’s presence on the shop floor is both reassuring and inspiring, as he consistently goes above and beyond to support his colleagues and drive the team’s success.

Always Learning, Always Growing

José’s dedication to expanding his knowledge and skills has been a driving force behind his remarkable achievements. From learning the company’s machinery to engaging with experts outside of the facility, José wants to know everything. Whenever equipment manufacturers or external technicians visit Olli Salumeria, José is right there, absorbing every bit of information they share. His colleagues note how he sticks to these experts like glue, asking questions and seeking to understand the intricacies of the machinery. This hands-on approach has expanded José’s technical knowledge and positioned him as the go-to person for troubleshooting and maintenance issues.

Always eager to share what he’s learned, José’s mentorship has been instrumental in upskilling the team, allowing them to handle complex maintenance tasks with confidence. This collaborative learning environment has not only enhanced the technical capabilities of the team but has also built a strong sense of camaraderie and mutual support.

José’s achievements at Olli Salumeria are deeply rooted in his meticulous nature, adaptability, and desire to learn. This quiet leader has helped foster a collaborative and positive work environment and has been instrumental in the team’s operational efficiency and overall success. Through his dedication and supportive nature, José has become a cornerstone of the Olli Salumeria team, driving continuous improvement and creating a lasting impact.

Want to know more? Read about more Faces of the Frontline, and their stories stories in our ebook.