Case study
Fertinger Automotive Poland and modern maintenance management with QRmaint system
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.
Fertinger Automotive Polska is a leading manufacturer of innovative fluid transmission lines for passenger cars. The company has been operating on the Polish market since October 2015. As a branch of the renowned Fertinger Group from Austria, a company with 75 years of tradition, Fertinger Automotive Polska consistently strives to be a leader in its industry.
Fertinger Automotive’s comprehensive solutions include designing and manufacturing air conditioning, ventilation, steering and other fluid transport systems. Their reliability and high quality are confirmed by numerous positive customer audits, recommendations and IATF 16949:2016 and ISO 9001:2015 certificates.
As part of our new article and reference development, we analyzed the case of the implementation of the CMMS QRmaint system at Fertinger Automotive Polska. Our team had the pleasure of talking to Szymon Wąsik, Head of the Maintenance Department at Fertinger Automotive Polska . The aim of our conversation was to understand the challenges the company faced in the area of maintenance and how the implementation of the CMMS QRmaint system contributed to solving them. Find out more in our article.
Precision in dynamic production, or what are the challenges in maintaining traffic in the automotive industry?
Before implementing the QRmaint system, Fertinger Automotive Polska, as a company with a dynamically changing production plan, faced a number of challenges in maintenance management. Szymon Wąsik, Head of the Maintenance Department, indicated individual areas that required improvements:
- Lack of electronic documentation registration: The main problem was the ubiquitous paperwork. The previous program used in the company was outdated and required support with paper failure registration cards. This, in turn, led to loss of information and unreliable reports.
In the company, I was primarily striving for a complete transition to electronic documentation registration . I knew that with the right system we could eliminate the huge amount of paperwork generated by traditional failure cards.
Szymon Wasik
Head of Maintenance Department
- Risk of information loss and lack of control: Many service requests that were not recorded centrally were lost in the daily rush of tasks. This, in turn, led to incomplete actions and frustration.
Many reports simply disappeared if they were not recorded, which led to frustration and unfinished work. My main goal was to create a central place where the entire history of failures and department activities would be recorded . We wanted to be able to go back to each failure, analyze it, which would allow us to plan effective preventive actions and gain more control.
Szymon Wasik
Head of Maintenance Department
- Inefficient maintenance planning: Dynamic changes to the plan resulting from changes in order quantities made it difficult to precisely plan maintenance and keep machines in constant readiness.
- Limited interdepartmental communication: Issue reporting was primarily done via email, which limited the involvement of other departments, such as production, in the defect reporting process.
- Lack of centralized cost and KPI monitoring: The company needed a tool to effectively track KPIs and maintenance costs. This was previously done partially manually or not in specific areas.
QRmaint implementation and fully comprehensive UR operations management
After a thorough analysis of the CMMS solutions available on the market, Fertinger Automotive Polska made a strategic decision to implement the QRmaint system. This choice was dictated primarily by the key features of QRmaint, which perfectly matched the identified needs of the company:
- Ease of reporting faults thanks to QR codes: Currently, work is based on these QR codes. This improvement has opened the way to broad employee involvement in the process of reporting problems.
At the moment, all of our machines are marked, which allows for easy reporting of faults . This is extremely convenient. I wanted to involve other departments in the process of reporting problems, and QR codes make this task much easier for production managers and functional people on the floor.
Szymon Wasik
Head of Maintenance Department
- Comprehensive, electronic documentation: QRmaint enables a complete transition to electronic recording of failures and service activities. The ability to attach photos and detailed descriptions provides a full history of each intervention, which eliminates the problem of lost information and lack of reliability.
Now we have full verification. We no longer need paper documents to confirm the reliability of the activity because we have full control over it.
Szymon Wasik
Head of Maintenance Department
- Automatic scheduling of inspections: The system allows for easy planning of cyclical inspections, which are automatically generated in the schedule. This significantly facilitates preventive management and communication with the logistics department regarding machine availability.
- Quick access to information and KPI data: QRmaint allows you to monitor key performance indicators such as MTTR (Mean Time To Repair).
If I set a certain time, when – how often – the machines should be inspected, then such a schedule is created in the system. QRmaint allows me to easily collect and analyze this data, which is invaluable in making informed decisions.
Szymon Wasik
Head of Maintenance Department
- Subscription model: A monthly subscription, instead of having to purchase a large license, turned out to be a convenient solution that helped and accelerated the implementation of the tool in the shortest possible time.
Future prospects in the automotive industry: Measurable benefits and development plans
After several months of intensive use, Fertinger Automotive Polska is already noting measurable benefits from implementing QRmaint:
- Increased documentation efficiency and data reliability: The system provides full documentation of all activities, including minor ones that may have previously been omitted from reports.
The QRmaint system is certainly a great convenience for all employees, because they no longer have to manually note down all the activities performed during the day. They just need to enter the data into the system, and then they can easily download a comprehensive report of their work.
Szymon Wasik
Head of Maintenance Department
- Improved communication and collaboration: With QRmaint, information about failures and repair status is available to all parties involved, speeding up processes and preventing misunderstandings.
- Troubleshooting support: Access to fault history and photos, for example in the case of problems with control cabinets, significantly reduces the time needed for diagnosis and repair.
We had a situation where a technician was looking for a problem in a control cabinet. Because we had a photo taken in the QRmaint CMMS system, we were able to determine that the wrong safety relay was used, which saved us a lot of time.
Szymon Wasik
Head of Maintenance Department
- Positive reception among technicians: Maintenance department employees are pleased with the simplifications provided by the system, eliminating manual note-taking and streamlining their daily work.
Looking to the future, Fertinger Automotive Polska has ambitious plans for further development and integration of QRmaint:
- Extension of the spare parts warehouse: A key priority is the implementation of spare parts warehouse management in the QRmaint system, which will allow for even better control over costs and component availability.
- Potential extension to the technical department: Consideration is being given to including technical department employees in the system, which will further optimize processes.
- Further exploiting the full potential of the system: Szymon Wąsik is actively exploring additional functionalities of QRmaint to fully utilize its capabilities to further streamline operations.
Summary
The implementation of the QRmaint CMMS system at Fertinger Automotive Polska turned out to be a strategic move that significantly improved the efficiency of maintenance management. Thanks to its ease of use, comprehensive documentation and data analysis capabilities, QRmaint has become an indispensable tool in the daily work of the department.
Absolutely, I would recommend it. We see tangible benefits – from the ease of reporting failures, through a full repair history, to more efficient maintenance planning. It’s a tool that really streamlines our operations.
Szymon Wasik
Head of Maintenance Department
If your company is facing similar maintenance challenges, contact us! The QRmaint team will be happy to show you how our solution can optimize your processes, improve efficiency and bring tangible benefits.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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The QRmaint system is a piece of software that perfectly satisfies the needs of Industry 4.0.
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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.
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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.
Associate Manager of the Maintenance Department
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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.
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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.
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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.
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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.
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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.
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I set up QRmaint myself in one evening, and already in the following days there were reports of failures by technicians and serial workers :)
Production Director
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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