Automotive Parts Manufacturer: 800 Workers, 24/7 Operations
How an automotive supplier saved $294,400 annually and achieved 99% respirator compliance across all three shifts
800
Manufacturing Workers
83%
Cost Reduction
$294K
Annual Savings
24/7
Shift Coverage
Company Overview
Precision Automotive Components is a Tier 1 automotive supplier manufacturing brake systems, suspension components, and drivetrain parts for major OEMs. The facility operates 24/7 with three shifts covering 800 production workers.
Workers are exposed to welding fumes (hexavalent chromium), metal grinding dust, paint spray operations, and cleaning solvents—requiring half-mask elastomeric respirators and PAPRs. OSHA 1910.134 compliance is critical for avoiding citations and maintaining customer certifications.
Quick Facts
- Tier 1 automotive supplier
- 800 production workers
- 3 shifts (6am-2pm, 2pm-10pm, 10pm-6am)
The Challenge: Shift Worker Coordination Nightmare
Previous process required workers to schedule occupational health clinic appointments during business hours (8am-5pm). This created massive scheduling conflicts for 2nd shift (2-10pm) and 3rd shift (10pm-6am) workers, who had to take time off to attend appointments.
The Solution: 24/7 Online Evaluations
The company implemented RespiratorTest.com with 24/7 access for all three shifts. Workers completed evaluations during breaks, before/after shifts, or at home—eliminating production downtime and scheduling conflicts.
99%
Compliance Rate
Up from 52% in 5 weeks
$294K
Annual Savings
83% cost reduction
2,340
Production Hours Saved
Zero production downtime
5 weeks
Full Rollout
All shifts compliant
"Coordinating respirator medical evaluations for 800 workers across three shifts was impossible with traditional clinics. Our 2nd and 3rd shift workers couldn't make daytime appointments without taking time off, and we were bleeding production hours. RespiratorTest.com solved this perfectly. Workers on all shifts complete evaluations whenever it's convenient—nights, weekends, breaks. We went from 52% to 99% compliance in 5 weeks and saved $294,000 annually. Our OEM customers love that we have real-time compliance dashboards. This platform should be standard in every 24/7 manufacturing facility."
Jennifer Chen, CSP
EHS Manager, Precision Automotive Components
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