Case study

Implementation of QRmaint CMMS system: Cedrob Foods SA

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

Maintenance requirements in production plants differ to a large extent in the specifics of production and the machines used. This aspect is even more pronounced in food companies, where several departments of the same company may be dependent on completely different maintenance operations of machines and devices. Therefore, everything comes down to the specifics of production, and consequently, the diversity and greater complexity of operational tasks for maintenance departments. This also leads to the immediate conclusion that maintaining standards in different locations is even more difficult when companies do not have standardized processes and uniform procedures and management systems.

Such tasks are among the challenges at Cedrob Foods , which consists of 5 production plants. With five food processing production plants across Poland, the maintenance activities they conduct differ in each facility due to the individual adjustment of food processing processes and production lines.

More than a year has passed since the implementation of the CMMS system in Cedrob Foods, and Mr. Jakub Skowroński is responsible for the entire operation and coordination of the actual implementation “and for coordination of the implementation in the largest plant”. As an experienced implementer, coordinator for optimization in the maintenance department, who has worked not only with CMMS , but also with ERP systems, such as IFS, and therefore – vast experience in working with the implementation of IT systems.

QRmaint had the great pleasure of talking to Mr. Jakub about the implementation of the QRmaint CMMS system at Cedrob Foods. Moreover, thanks to the professional implementation of the CMMS system by Cedrob, we had a good opportunity to learn many important indicators regarding the optimization and improvement of the efficiency of UR departments based on hard numbers. Check out more in the article below.

cedar food facility

Maintenance Challenges at Cedrob Foods

Cedrob Foods is a Polish company specializing in the production of high-quality poultry and meat products. It supplies its products to retail chains, catering and individual customers in the country and abroad. Strictly, the plant located in Sosnowiec processes poultry and, to some extent, pork and beef. For example, the plant in Sosnowiec receives raw material after slaughter and produces a finished product from it. Their flagship product is, among others, Pasztetowa Duda, the taste of which is probably known to customers all over Poland.

Already these few words at the beginning, talking about what end products Cedrob Foods receives, give a good idea of ​​what kind of machines may be inside the company for producing this type of food.

Examples of machines used to produce this type of food:

Preparation and Mixing

It includes machines for grinding and chopping meat, as well as for mixing and emulsifying it with other ingredients to obtain a uniform mass of the product.

Processing and Cooking

Here you will find equipment for pre-treatment and shaping of meat products, followed by cooking and pasteurization in various thermal units, followed by rapid cooling .

Finishing and Quality Control

This includes packaging lines for portioning and packaging finished products.

Also, knowing the scope of machines and equipment needed to work in this type of plant, we can better imagine how complex the processes take place in the company when it comes to UR activities in order to deliver the highest quality products.

In a conversation with Mr. Jakub Skowroński, we learned about a number of dependencies and challenges that the company had to deal with before implementing the QRmaint CMMS system. Here are some of them:

  • Inefficient telephone ticket handling: Communication regarding outages and service needs relied on telephone calls, making it difficult to track tickets, prioritize tasks, and ensure a timely response.
  • Lack of a centralized data system, where the records of processes and tasks were kept using the MS Excel application: Key information about machines, inspections, repairs and maintenance tasks was scattered in spreadsheets, which led to difficulties in accessing current data, analyzing performance and making informed decisions.

cedar food 2

The two most important challenges in the FMCG industry – because we are in the industry of producing fast-moving goods – are, firstly, that the customer wants to buy a product of the highest quality at an affordable price. as cheaply as possible. And consequently, the plant that wants to produce such a product must have the most standardized processes possible.

The second issue is the speed of response to orders. This is directly related to the very short shelf life of products. In other words, the customer would like to place an order today and receive it the next day – on average within 24 to 48 hours – which leaves very little time for managing this product.

Jakub Skowronski

Optimization Coordinator

  • Lack of ability to manage tickets: There was no dedicated system for recording, monitoring and managing service tickets, which prevented effective work planning and measurement of response times.
  • Difficulty in automated task management: The lack of a systematic approach to planning, assigning and tracking maintenance tasks resulted in inconsistent activities, omission of important activities and difficulties in coordinating team work.

Strictly the most important challenge of maintaining traffic in such large plants as Cedrob Foods is the fact that we are dealing with large nest production. This provides great flexibility, because if production is stopped in a given nest, the technological process can be switched to another.

The direction of development of the Cedrob organization is the transition from nest-based to linear production, where the system of machines and devices should function without disruptions, with measurable efficiency.

Jakub Skowronski

Optimization Coordinator

  • Lack of mobility: Maintenance workers lacked access to information and reporting capabilities in the field, delaying problem diagnosis and task execution.
  • Lack of a centralized equipment database: There was no comprehensive and up-to-date database containing information on all machines and equipment, their specifications, service history and location, which made asset management and maintenance planning difficult.
  • Difficulties in easily ordering parts for machinery and equipment: The process of ordering necessary spare parts was inefficient and time-consuming, which prolonged machine downtime and increased maintenance costs.
  • Deficiencies in cost control and accounting: The lack of detailed tracking of maintenance costs made it impossible to optimize the budget and identify areas where savings could be achieved.

I think the biggest challenge for the maintenance department is to organize work in a way that allows for anticipating corrective actions through prevention and prediction. In this way, the maintenance department does not allow for unplanned machine downtime. This is because at a time when we have very little time to produce goods and deliver them to the customer, every minute of downtime is very expensive.

Jakub Skowronski

Optimization Coordinator

  • Lack of clear insight into maintenance activities, inability to effectively review the condition of the machinery park: The management did not have a clear picture of the current activities of the maintenance department or the current technical condition of the machines, which made it difficult to make strategic decisions regarding investments and modernization.
  • Lack of an effective reporting system: The inability to generate detailed reports on failures, downtime, costs and efficiency of the maintenance department made it impossible to measure progress and identify areas for improvement.

cedar food

Solution: Implementation of CMMS system

After taking action to optimize the maintenance work at Cedrob Foods, initiated by Mr. Jakub Skowroński, optimization coordinator, the efficiency of the UR department was found to be improved in many areas. The QRmaint CMMS system improved the work in the areas listed below:

  • Case Management Capability: With the built-in functionality of the app, users can efficiently log, monitor and manage all service calls.
  • Task Management Capability: QRmaint CMMS app provides tools to schedule, assign, track, and close maintenance tasks.
  • Equipment Database: The built-in database in the app allows you to store detailed information about all your machines and equipment, including their specifications, service history and location.

One of the main decisions taken when implementing the QRmaint system was the positive reception of the system – both in technical terms and from the perspective of the UR department employees who use it on a daily basis.

The second reason for the implementation was the lack of a comprehensive tool that would handle all UR tasks along with a centralized database, which was becoming more and more necessary with the increasing optimization of production processes.

Jakub Skowronski

Optimization Coordinator

  • Possibility to order parts for machines and devices: The application functionality supports the process of ordering necessary spare parts, improving communication with suppliers and tracking orders.
  • Cost accounting: The CMMS QRmaint application has modules for tracking and analyzing costs related to maintenance activities, allowing you to generate cost reports. I have not tested this functionality yet, so I cannot 0/1 sign off.
  • Possibility to work on dashboards – overview of the machinery park status: Built-in dashboards in the application visualize key indicators regarding the machinery park status, facilitating quick insight into the most important information.
  • Reporting: The application offers advanced reporting features, allowing you to generate a variety of reports on tickets, tasks, costs, failures and other relevant data.
  • Mobility: Thanks to the mobile features in the app, maintenance personnel can access the system and update information from anywhere using mobile devices.

Summary

The implementation of the QRmaint CMMS system in the production plants belonging to the Cedrob Group is an example of the power of transformation in maintenance management. As the case of Cedrob Foods has shown, the key to success is the implementation of standardized systems that ensure data centralization. In addition, the focus on process automation and improving operational efficiency has definitely had an impact on the increase in productivity.

Is your company also facing maintenance challenges? Do you want to streamline your processes and achieve tangible benefits like Cedrob Foods?

Contact us today to learn how QRmaint CMMS can revolutionize your business.

 

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

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

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

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

Maintenance Manager

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