Case Study

Powering 30 Sites Nationwide: Costco

National PPM and emergency cover across all 30 Costco warehouses in the UK. Centralised job tracking, fault analysis, and upgrade planning delivered measurable results within the first year.

43% Repeat fault reduction
200+ Service visits per year
<24h Average response time
30 UK sites covered
The Goal

One Contract, One Standard, 30 Warehouses

Costco operates 30 warehouse locations across the UK. Each site relies on compressed air for dock door operation, tyre inflation, and general maintenance. Before working with Airmech, Costco used multiple local contractors with no centralised tracking, no consistent service standard, and no single view of compliance status.

The brief was straightforward: consolidate everything under one national contract. One phone number for breakdowns. One set of service records. One report that shows exactly what is happening across every site.

PSSR compliance was a particular concern. With 30 sites and mixed compressor ages and brands, keeping written schemes current and coordinating insurance inspections was falling through the cracks.

“Reduced repeat compressor faults by 40% across our UK sites and simplified our PSSR paperwork.”

Operations Manager, National Distribution Centre
The Solution

National PPM With Centralised Reporting

Airmech designed a national service agreement covering planned preventative maintenance, emergency breakdown response, and full PSSR compliance management for all 30 sites.

What the contract covers

  • Scheduled PPM visits based on actual run hours at each site, not a generic annual calendar
  • 24/7 breakdown line with sub-24-hour average response time
  • Digital job sheets sent to site contacts and head office after every visit
  • Centralised asset register covering every compressor, dryer, and receiver across all 30 sites
  • PSSR written schemes maintained and insurance examinations coordinated
  • Quarterly reporting: work completed, faults found, recommendations, and compliance status

Every site was audited in the first eight weeks. Compressors were logged, service histories reconstructed where possible, and a baseline condition assessment completed. From there, each machine was placed on the right service interval based on its age, type, and duty cycle.

The Impact

43% Fewer Repeat Faults in Year One

Within the first 12 months of the national contract, Costco saw a 43% reduction in repeat compressor faults across all UK sites. The combination of proper service intervals, genuine OEM parts, and centralised fault tracking meant problems were caught and fixed properly the first time.

43% reduction in repeat faults. Proper root cause analysis and parts quality eliminated recurring issues.
200+ service visits completed per year across 30 sites. Every visit tracked with digital job sheets.
<24h average emergency response time. Priority scheduling for contract sites means faster attendance.
100% PSSR compliance across all 30 sites. Written schemes current, examinations scheduled, records centralised.

Costco now has a single point of contact for every compressed air issue across the UK. One phone number, one reporting structure, one standard of service from Scotland to the South Coast.

Services Deployed

Compressor Servicing

Planned preventative maintenance on the right interval for each machine. Filters, oil, separators, and belts replaced based on run hours.

Breakdown Repair

24/7 breakdown line with priority scheduling for contract customers. Sub-24-hour average response across all 30 sites.

PSSR Compliance

Written schemes maintained for every pressure system. Insurance examinations coordinated. Full audit trail available on request.

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