Implementation of QRmaint CMMS system at Konkol slaughterhouse

Food processing companies operate with very tight margins. Whether in production or distribution, margins are typically very low. Therefore, it is important to maintain production continuity at the highest level. Food processing companies cannot afford unplanned machine downtime, as this leads to lost revenue and, subsequently, a loss of profitability. To counteract unplanned downtime and improve workflows and communication, these companies implement a CMMS system.

QRmaint had the great pleasure of speaking with Mr. Marcin Sikora, Head of the UR Department, who is responsible for maintenance at the Konokol poultry slaughterhouse . This company has implemented the QRmaint CMMS system to improve the maintenance processes of machinery and infrastructure in two of the plant’s production halls.

In this article, we describe the implementation of a CMMS system in a food processing company. We explain how companies in this industry improve the quality of their maintenance work and prevent micro-outages in production. See for yourself why QRmaint’s CMMS system offers significant added value for your business operations.

Konkol company store

Konkol Poultry Slaughterhouse – a global leader in food processing

Konkol began its business in 1990 with poultry farming. Today, the company specializes in poultry slaughtering and trading. The company headquarters, originally located in Somonino, has since relocated to modern facilities in Niestępów. The facility currently meets the high standards and requirements of the European Union. The company is developing very dynamically, which is also reflected in two factory expansions.

The Konkol poultry slaughterhouse offers its customers high-quality products and boasts many years of industry experience. The company meets all legal requirements for the slaughter and butchering of poultry meat and is licensed for the meat trade in the European Union. The company boasts modern technical equipment, including two warehouses, two production halls, and numerous machines for deboning, filleting, and packaging meat.

A key element of a well-functioning plant is the maintenance department, headed by Marcin Sikora. The team consists of nine maintenance technicians/mechanics who ensure the smooth operation of over 200 pieces of equipment in both the clean and dirty parts of the plant. Together with 15 foremen, they ensure production continuity and the high quality of the products offered.

Production hall: Dirty part

• This is the area of ​​the facility where the initial processing of the poultry takes place.
• Includes processes related to live animals and heat treatment.
• It is equipped with around 50 devices and machines.

Production hall: Clean room area:

• This is the area of ​​the plant where the final processing of poultry meat takes place.
• This includes processes such as boning, filleting and packaging.
• It is equipped with around 150 devices that ensure high hygiene standards and high product quality.

 

Challenges in the food industry: Konkol poultry slaughterhouse 

Trotz seiner rasanten Entwicklung und modernen Anlagen steht der Geflügelschlachthof Konkol vor mehreren betrieblichen Herausforderungen. Diese beeinträchtigen die Produktionseffizienz und die Einhaltung hoher Standards. Im Folgenden sind die wichtigsten Bereiche aufgeführt, in denen das Unternehmen Korrektur- und Verbesserungsmaßnahmen ergriffen hat:

Lack of effective communication: The slaughterhouse struggled with an inadequate information-sharing system between maintenance workers and supervisors. This directly led to delays in responding to outages and made coordination of activities difficult. In many companies, the lack of clear communication channels and standardized procedures for reporting technical issues results in inconsistent or delayed information sharing.

Delays in repairs: Like other food processing plants, Konkol Slaughterhouse struggled to quickly diagnose and resolve malfunctions. These problems resulted from a lack of appropriate error reporting tools. Delays in repairs led to extended machine downtime, negatively impacting productivity and timely order fulfillment.

Production downtime : The company was struggling to meet deadlines and minimize machine downtime caused by breakdowns. This resulted in a lack of availability and sometimes delays in production planning. It’s clear that machine downtime leads to financial losses, delays in order fulfillment, and customer dissatisfaction.

Specialized machinery: The machinery at the Konkol poultry slaughterhouse is custom-built and requires specialized expertise, monitoring, and control for maintenance. This has sometimes presented additional challenges for the maintenance department. This is primarily due to the fact that working with this type of machinery requires quick access to technical documentation and machine diagrams. Otherwise, their lack makes diagnosis and troubleshooting difficult.

Inefficient data management: Time-consuming administrative tasks and MS Excel-based reports often resulted in employees wasting significant time entering data into computers. This increased the risk of errors and delayed the decision-making process. Furthermore, the lack of an integrated data management system made data analysis, trend detection, and optimization measures difficult.

How has the Konkol poultry slaughterhouse improved its machine maintenance?

The implementation of QRmaint’s CMMS system at the Konkol poultry slaughterhouse contributed to a change in the way maintenance is handled. Indeed, the CMMS system contributed to a significant reduction in machine downtime costs and better optimization of production processes. What were the other impacts? Below are some of the key points of the CMMS implementation at the Konkol slaughterhouse: 

Precise downtime monitoring: Implementing a system for measuring microdowntimes, even down to 1 minute, enables precise analysis of failure causes and the implementation of corrective actions. The QRMaint CMMS system facilitates data collection and analysis.

Efficient fault reporting: Simplification and optimization of the fault reporting process, resulting in shorter response and repair times. The CMMS system enables fault reporting from mobile devices.

Our industry environment is difficult and highly demanding, which is why the QRmaint CMMS system helps us resolve issues more quickly. Since we work with live animals to a certain extent, they are not a typical production raw material. To maintain product freshness, we need to resolve errors quickly and effectively.

Marcin Sikora

Maintenance Manager

Mobile employee service system: The implementation of a mobile employee service system throughout the production hall, equipped with mobile devices, has significantly facilitated communication and coordination of activities.

Improved communication: The implementation of clear communication channels and standardized procedures for reporting technical issues using CMMS QRmaint has improved communication between supervisors and mechanics.

For us, every minute of downtime is very costly. Thanks to the QRmaint system, we closely monitor operations and can even measure micro-downtimes of machines when a fault occurs that is corrected by the machine operator himself. Because we now also accurately measure repair turnaround times, we can implement an efficient compensation and reward system for the maintenance team.

Marcin Sikora

Maintenance Manager

Accurate measurement of machine downtime: The implementation of the CMMS system made it easy to measure machine downtime. This actually enabled the identification of bottlenecks in the production process.

Efficient spare parts inventory management: The CMMS system enabled the management of the spare parts inventory. This will enable QRmaint to provide quick access to the required parts in the near future and reduce repair times.

We previously had two external warehouses in two different halls, which have now been consolidated. We are currently in the process of migrating 100% of our warehouses to the QRmaint CMMS system. All spare parts inventory management processes are carried out in the CMMS system.

Marcin Sikora

Maintenance Manager

Use of QR codes: The QRmaint CMMS system offers the ability to use QR codes to mark machines. This will facilitate the identification and management of equipment and infrastructure on both production floors.

Summary

The implementation of the QRmaint CMMS system proved to be an important step in optimizing maintenance processes at the Konkol slaughterhouse. This step brought tangible benefits in the form of reduced downtime costs and improved communication. One of the most important features, however, is the easy fault reporting, which both users of the QRmaint CMMS application and management are very satisfied with.

I would especially recommend the QRmaint CMMS system to companies that have their own warehouse and workshop. It’s a system that increases efficiency and streamlines production processes.

Marcin Sikora

Maintenance Manager

If your company is struggling with costly downtime and inefficient maintenance management, contact us. We can help you optimize your UR operations today.

QRmaint’s CMMS system offers precise monitoring, mobile access, and efficient asset management. Schedule a free consultation and learn how you can optimize maintenance!