Introduction

At New Enterprise Stone & Lime Co., customer service remains at the core of operations. However, a gap was recognized—customers were not being serviced in the desired manner. Moving from a reactive to a predictive approach became a critical goal, not only to improve efficiency but also to enhance safety and ensure that products are delivered when needed.
One of the biggest challenges is workforce turnover. In the next five years, nearly 50% of the workforce is expected to transition, with experienced, 40-year veterans retiring. That leaves a knowledge gap for the next generation of employees. By implementing KCF Technologies’ monitoring equipment, the learning curve has accelerated, and overall operations have improved.

The impact of predictive maintenance has been significant. Over the past six months, about 2,000 triggers have been recorded, leading to 100 actionable insights—ranging from simple maintenance like greasing to preventing premature failures. This shift from reactive to predictive maintenance is key to keeping operations running smoothly.

The Role of Technology in Transformation

Jim Rokosky, Vice President of Information Technology, emphasizes the importance of having clear objectives when implementing new technologies. “You have to balance big ambitions with practical applications,” he says. Running pilot programs to prove value, engaging coworkers early, and measuring results are essential steps in ensuring a successful rollout.

Clean data is also critical. “AI can make really good decisions quickly, but it can also make really bad decisions quickly,” Jim notes. Ensuring data integrity and preparing the workforce for new technology are crucial for success. However, technology alone isn’t enough—it’s the people using it that make the difference. Without employee buy-in and understanding, even the best technology won’t provide value.

Early Success and Expansion

Larry Kessler, HMA Performance Manager, was one of the first to pilot KCF’s technology. “Within the first few weeks, an issue was caught that saved tens of thousands of dollars,” Larry shares. Over the next two months, even more success was achieved, proving the system’s value. After positive results at two pilot plants—one aggregate plant and one asphalt plant—the rollout expanded. With real-time actionable data and a predictive mindset, New Enterprise Stone & Lime is setting the foundation for a more efficient and future-ready operation.

By embracing predictive maintenance and leveraging technology, failures are not just being prevented—long-term success is being ensured for customers, employees, and the business.