Case study

Transforming Alu Menziken aluminum production with QRmaint

Everything was clear. We needed a digital foundation that would allow our teams on the production floor to work quickly and record data transparently, while providing management with the real-time analytics necessary to prevent future breakdowns before they even occur.

Viorel Osan – Maintenance Manager

In high-precision manufacturing, equipment downtime directly jeopardizes delivery timelines, operational margins, and plant overall equipment effectiveness (OEE). Alu Menziken, a premier manufacturer of high-grade aluminium components, faced mounting engineering challenges related to unscheduled production halts on their production lines.

Prior to implementing QRmaint, the plant suffered from localized blind spots. While maintenance technicians were highly skilled, their operational workflows were primarily governed by legacy paper tracking sheets and fragmented spreadsheet tables (like the “central” data logs).

What was the Root Cause?

Lack of Centralized Failure Documentation: Breakdowns were addressed quickly on a practical level, but technical details regarding the true mechanisms of failure were rarely structured systematically. Consequently, engineering teams could not map or spot repetitive failure modalities.
Fragile Preventive Maintenance Framework: Scheduled interventions relied significantly on human memory and scattered calendar notes. Complex machinery drifted outside standard operational tolerances, triggering catastrophic, unexpected breakdowns.
Obscured Asset Lifecycle Data: Tracking MTBF and MTTR manually introduced structural time-lags. By the time charts were updated, the operational insights were historic rather than actionable.

“Everything is clear, yes. We needed a digital anchor that allowed our teams on the floor to execute fast, record data transparently, and give leadership the real-time analytics required to prevent the next breakdown before it occurs.” > — Viorel Osan, Maintenance Manager, Alu Menziken Romania

The Solution: Deploying QRmaint CMMS

The deployment of the QRmaint CMMS platform focused on removing technical and administrative friction directly from the production floor. The QRmaint onboarding team tailored the cloud solution to accommodate rapid technician adoption, asset tagging via QR codes, and real-time operational dashboarding.

Key Solution Components Implemented:

Instant Mobile Ticket Assignment: Technicians scanning a localized machine asset tag could instantly view its exact repair history, digital blueprints, and submit standardized logs.
Automated Preventive Maintenance (PM) Schedules: Calendar-driven and counter-driven alerts shifted the department from reactive corrective loops into planned, predictive workflows.
Live KPI Infrastructure: Mathematical tracking for MTBF and MTTR was automated via live data pipelines, displaying operational health directly to management.

“Everything is clear, yes. We needed a digital anchor that allowed our teams on the floor to execute fast, record data transparently, and give leadership the real-time analytics required to prevent the next breakdown before it occurs.” — Viorel Osan, Maintenance Manager, Alu Menziken Romania

Analysis: 4 Years of data performance

The success of the deployment is structurally vindicated by the plant’s official data tracking spanning from January 2022 through December 2025, so blow we tooked some key metric breakthroughs:

Evolution of MTBF (Reliability Vector): In the baseline year (2022), the facility operated with highly constrained MTBF periods, bottoming out at 14.4 hours in May 2022. Following systematic QRmaint execution and predictive tracking, the intervals grew longer. By December 2023, the plant recorded a stellar 79.1 hours of continuous production between failures—a 267% peak increase relative to the prior baseline lows. The system reliability maintained a structurally higher floor through 2024 (peaking at 67.3) and 2025 (peaking at 73.0 in September).

“Seeing our Mean Time Between Failures climb from a low of 14.4 hours back in 2022 to peaks over 70 hours is proof that systematic, automated preventive maintenance works. — Viorel Osan, Maintenance Manager, Alu Menziken Romania

Control Over MTTR (Maintainability Vector): Critically, while equipment was running significantly longer between technical failures, the average time required to restore broken machinery (MTTR) remained under tight control. Backed by quick access to parts records and standard procedures on the mobile app, MTTR repeatedly dropped to highly optimized floors of 0.5 hours in late 2024.

Measurable results with business impact base on QRmaint solution

Transition to Predictive Engineering: Automated PM schedules drastically reduced sudden, costly manufacturing friction across aluminum extrusion and fabrication assets.
Elimination of “Data Silos”: Outdated offline tracking methods were transformed into a single source of truth accessible instantaneously via floor mobile devices.
Strategic Capex Clarity: The data allowed Viorel Osan and the plant’s leadership team to isolate exact assets demonstrating high failure recurrence patterns and justify precise maintenance or equipment investments.

Summary

The collaborative implementation between QRmaint and Alu Menziken Romania demonstrates that digital transitions in manufacturing yield structural improvements when software usability meets plant floor practicality. By modernizing their maintenance ecosystem, Alu Menziken successfully turned complex operational metrics into an unyielding competitive advantage.

“The collaborative synergy with the platform turned our complex maintenance logs into a clean, unyielding competitive advantage on the factory floor.” — Viorel Osan, Maintenance Manager, Alu Menziken Romania

Learn from our clients and their stories

We work with different sized businesses and all types of industries. The thing they all have in common is that they trusted us to keep their equipments and properties safe and sound.

Interesting insights into optimizing charging infrastructure with software. Does QRmaint meet all our requirements and enable us to meet the challenges of modern maintenance in multiple locations at the same time? We believe that QRmaint is a key element in ensuring that our conveyors and sorting systems are in the right condition so that we can keep our quality promises to our customers in the future.

Sandro Wanko

Manager

With QRmaint, we have found a solution that allows us to make our maintenance processes for production equipment much more structured and transparent. Maintenance activities, fault reports and tasks can be recorded centrally and tracked reliably. We particularly value the ease of use and the quick access to all important information in our daily work. QRmaint helps us work more efficiently, shorten response times and improve equipment availability over the long term.

Christian Baur

Maintenance Manager at Carl Walther GmbH

QRmaint has significantly streamlined our maintenance processes. All tasks, breakdowns, and inspections are now centrally recorded, transparent, and verifiable at any time. The mobile app saves time in our day-to-day work, and its clear structure ensures greater efficiency and fewer downtimes.

Felix Jakob

Procurement

We use the software for both preventive maintenance and emergency issues. In particular, the feature that allows us to scan with a cell phone to create work orders has given us a clear advantage in recording tasks and carrying them out in an organized manner.

Tobias Schmitt

CEO

QRmaint has exceeded our expectations in every way. It is so well designed and effective that I can confidently say it is the best software I have ever worked with.

Brian A. Pierce

Vitakraft, U.S.

The software effectively helps us keep track of and manage service requests in our day-to-day operations. We particularly appreciate how easy it is to schedule and track routine tasks, such as cleaning and maintenance.

Jens Kueppers

Maintenance Manager

The support is impeccable and always has an open ear for questions and ideas, and the SaaS structure means that there are always extensions available

Maintenance Technology Team

Schäfer Metallurgie GmbH Hennef

I think the UR department's biggest challenge is to organize its work in a way that allows it to get ahead of corrective actions through prevention and prediction. In this way, the UR department prevents unplanned machine downtime from occurring. This comes from the fact that when we have very little time to produce goods and deliver them to the customer, every minute of downtime is very costly.

Jakub Skowroński

Optimization coordinator

I see a big improvement, especially in the speed with which employees report faults. In the past, it used to happen that we had already taken action and completed the repair long before we received a formal report. Now this happens much, much less often (...)

Maciej Szypryt

Maintenance Engineer at Keylite Roof Windows

The QRmaint system is certainly a great convenience for all employees, as they no longer have to manually note down all the activities they perform during the day. All they have to do is enter the data into the system, and then they can easily download a comprehensive report of their work.

Szymon Wąsik

Head of Maintenance Department

QRmaint has significantly improved our workflow, especially in terms of recording key data for annual reviews. The ability to track and document issues has proven invaluable, providing valuable information to optimize operations. The system provides excellent value, and its benefits are evident.

Josh Magkasi

Engineer Technician

The biggest benefit for me in QRmaint is the attachments that I attach scans to, and the comments that keep me up to date with what's going on at the booth. These hints from the comments, which appear in the cloud, allow me to see in real time what is going on.

Agnieszka Stachowicz

Systems assistant for maintenance

The QRmaint system significantly improves our processes. It gives us better control over submissions, reviews and resources. The system also enables us to analyze data, which allows us to optimize costs and make better decisions. QRmaint's mobile application facilitates the work of our technicians in the field, giving them access to the necessary information in real time. In our experience, accessing the protocol in the app alone saves us about 30 minutes to 60 minutes per inspection.

Daniel Małysa

CEO of ProFM

One of the most valuable features of the QRmaint system for us, turned out to be the ability to comment on requests and attach photos and videos. This visual form of communication has significantly sped up the process of diagnosing problems. Instead of describing a malfunction in words, employees can now present it in a pictorial manner, which eliminates misunderstandings and allows for faster understanding of the problem.

Tomasz Bartkowski

Brand Manager at Bartkowscy Bakery

We are thrilled with the simplicity and effectiveness of the program! After only a short time, we noticed a significant improvement in our internal processes.

Christopher Stinges

Sales Manager and Certified Bread Sommelier

We analyzed the market. We wanted to choose a service where price goes hand in hand with quality. We had one assumption - we have to understand the program in an hour. If we don't understand it in that time, it is not for us. QRmaint is a very clear program, made for Maintenance. Here there was no problem.

Jarosław Kurach

Maintenance coordinator

The system was very well received, and its implementation went smoothly. It won high praise among the auditors. In particular, in our case, the function of viewing the machinery park on interactive plans and the overall presentation of the most important information from the UR department proved very useful.

Marcel Menne

Head of maintenance

Customers quickly notice when equipment is damaged, and this can negatively affect our image. With QRmaint, defects are fixed in no time, which increases the number of people using our clubs.

Anna Socha

Manager

The QRmaint system is a piece of software that perfectly satisfies the needs of Industry 4.0.

Tomasz Wachowski

Deputy Technical Director

We plan to continue developing and using QRmaint to its full potential. Our goal is to further streamline maintenance processes, as well as to incorporate additional functions that will support warehouse management and other areas of the business. We are currently implementing a fault reporting process.

Raphael Groß

Employee of the Design Department

If someone wasn't responsible for the part in stock, we bought new ones. We generated additional costs. The second thing when it comes to the warehouse - in a situation where we have a description of the parts and we have them cataloged in the program, so that there will be no problem with purchasing the same ones. You don't have to look for them. They are sufficient in the program.

Tomasz Jaroszewski

Associate Manager of the Maintenance Department

The most important part for me is that my employees know how many work orders are left to be completed and what the priorities are. Technicians have access to all tasks in real time. We have basically completely eliminated situations which would occur frequently in the past, e.g. certain work orders were often missed, overlooked or entirely forgotten.

Arkadiusz Tetloch

Manager of Maintenance and Innovation

We wholeheartedly recommend QRmaint to other manufacturing companies. The system facilitates interdepartmental communication and offers many useful features that improve work efficiency.

Klaudia Mielczarek

Maintenance and Facility Specialist

The Qrmaint system, which was implemented in our business, has greatly enhanced both the work of our Maintenance team and the team's response to persistent production difficulties.

Rafał Topolski

Production Process Optimisation Engineer

Thanks to the QRmaint CMMS system we could finally forget filling out tons of paper. We now have easy access to the history of failures, repairs and services. Also the response time to each reported failure has been significantly reduced.

Anna Ciesielska

Process Engineer

Reporting a failure by scanning the QR code on the machine has technically ruled out any inaccuracies concerning the device affected by the problem submitted. Saving all the requests within the system results in an excellent overview of which machines are causing issues the most.

Krzysztof JANIK

Automation Service Supervisor

I divide my work at the company into 2 stages: 1. Numerous pointless phone calls, constant updates on the status of fault rectification, and a vast array of issues that went unresolved existed prior to the implementation of QRmaint. 2. When QRmaint is used, everyone is interested in staying informed, the ability to focus attention on pertinent issues, and 100% of reported issues are resolved.

Aleksander Penkowski

Head of the maintenance

I set up QRmaint myself in one evening, and already in the following days there were reports of failures by technicians and serial workers :)

Tomasz Pruszyński

Production Director

The QRmaint system replaced hundreds of emails, which, regardless of the subject matter, were sent to everyone on the list, instead of just to the individuals they were intended for. Previously, when the failure had already been taken care of, nobody really knew about it. Today we have an insight on an up to date status of each failure.

Mariusz Staniszewski

IT Department Manager

The system works flawlessly. The reaction time of our teams has significantly decreased. This is a much better communication model than phones and writing notes.

Maciej Hartfil

Dean, University of Physical Education, Warsaw

From the moment the Qrmaint system has been implemented at our company, it is still being adjusted to our needs - the functions are being adapted to the specifics of our industry, e.g.: there was no schedule in place when we got the program off the ground but now it not only exists- it looks pretty much like a Google calendar.

Jacek Turkowski

Property Maintenance Coordinator

QRmaint has proven to be a reliable, flexible company that is responsive to user ideas and feedback. The system has made our work easier, and its reporting functionalities have been well received by our clients.

Sławomir Pinkowski

SEO

The QRmaint system increased the competitiveness of our services within the property management industry. In addition to standard maintenance services, we can now provide our clients with a tool allowing them to quickly report any failures that may occur and to report on the work performed on their property.

Mateusz Czerwiński

The implementation of the QRmaint application turned out to be THE solution for the greatest challenge of all: instant damage control. The next step in the implementation will be to use it to support the work of those managing cleaning service companies.

Pawel Migacz

Managing Director

For us, every minute of downtime represents a very high cost factor. At this point, thanks to the QRmaint system, we have a close eye on operations and can even measure micro downtime of machines when a fault occurs that the machine operator fixes himself. As we can now also accurately measure repair turnaround times, we are able to introduce an efficient remuneration and reward system for the maintenance team.

Marcin Sikora