How an Exporting Textile Mill Transformed Maintenance Operations to Support large Scale Production

How an Exporting Textile Mill Transformed Maintenance Operations to Support large Scale Production

Laksana Established in 1997, PT. Laksana Kurnia Mandiri Sejati(Lakumas) is one of the most prominent textile spinning mill specialized in production of export quality synthetic yarn. The mill based out of Indonesia owns the pride of having exported yarn to Japan, U.S.A, Middle East etc.

The mill improved its revenues and profit margins to the stage of taking over Bandung spinning mill in 2006. Lakumas aims to produce quality yarn for knitting and weaving with a total capacity of 40,000 spindles for Acrylic / Cotton production line. The organization has bagged ISO 9001:2008 certification in 2014.

Lakuhas

Industry Textile Spinning Mills
Location Indonesia
Founded 1997

Problem Statement

With a good Year on Year growth, the spinning mill required a well organized system and processes in place to understand the maintenance workflow and master it to focus on core manufacturing processes. A CMMS system automating Preventive and Corrective Maintenance workflow to ensure a complete and quick service was needed.
They wished to maintain the full service history of machinery in a cloud environment which can be retrieved whenever on need. The full service history along with documents such as user manual, warranty card etc need to be available in a single location.

The concern felt that it would be nice if the CMMS system automated few production activities such as noting down the values of critical parameters at regular intervals so that any dangers associated with the breach in desirable values can be thwarted  and schedules triggered accordingly to perform corrective actions.

With large scale production the need for procuring, organizing and storing parts was felt. This was essential to ensure that there was no delay in supply of spares which is essential for a good performance on work orders.

Solutions Provided by InnoMaint

Corrective maintenance workflow ensured that no service requests fell through the cracks. This saved the day for Lakumas with quicker repairs. Even while working on scheduled PPM tasks, technician can raise a breakdown request. The system provides a provision for that. Hence the concerned stakeholders need not wait for the actual breakdown to occur.

InnoMaint  is flexible to the extent that any user who is not registered with the application can raise an emergency service request by just entering his name and mobile number. Rest of the details that constitute the profile can be filled later. It is also possible for any stakeholder to raise tickets instantly by just scanning the QR code pasted on the asset.

Before dispatch, the line managers can also view the dynamic visibility of workload of the technician. There is a provision for auto-assigning tickets. However based on the current workload or non-availability of technician, the ticket shall also be re-assigned. Ticket assignments can be conveniently done from anywhere round the clock. The technician receives notification on ticket assignment via push and email notifications in InnoMaint mobile app.

The application provided detailed, comprehensive and customizable reports for arranging quick meetings and arriving at well informed decisions on maintenance. The reports could be downloaded as ‘pdf’ as well. The Dashboard provided useful metrics for tracking performance of the technician such as engagement time, first time fix rates, on-time arrival etc.

The management leveraged the Solution Bank feature of InnoMaint available to the service technicians via easy to use & user friendly mobile app. The solutions to commonly occurring issues are usually created by senior technicians and approved by Operational Manager. Fixes to common and frequently occurring issues was delivered when the technicians required it providing instant help, on the field.

InnoMaint eliminated waiting time for spares with automatic reordering upon falling below a minimum level. The opening and closing stock during each transaction will be displayed to avoid discrepancies in actual stock level and in records.

Results

   20% improvement in Turn around Time
   Best management of corrective maintenance
   Complete Service history available digitally
   Improved usage of resources
   30% Improvement in availability of spares
✔   Ability to define unique checklist for each machine

How a chain of retail stores standardized
& tracked maintenance

How PMV Maltings delivered consistent
and increased production

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How Daifuku, a long-standing material handling equipment manufacturing giant, tracked technicians on-site for best engagement

How Daifuku, a long-standing material handling equipment manufacturing giant, tracked technicians on-site for best engagement

Daifuku is a a long-standing giant in business world with inception as early as 1937. It has witnessed a very long spell of solid, organic growth over the past eight decades and continues to dominate the global business arena. It is listed, at present, in the First section of Tokyo Stock Exchange which is a great pride and honour for any organization. The employee headcount has gone past 11,000. The firm was bestowed with METI Minister’s Award for Corporate Governance of the Year recently.
Daifuku is versatile in business offering Consulting, engineering, design, manufacture, installation, and after-sales services for logistics systems and material handling equipment. It has enormous experience in manufacturing and integration of automated systems. To list a few,
DAIFUKU
Industry Material-handling equipment company
Location Japan
Founded 1991
    • Conveying system
    • Transport system
    • Storage system
    • Sorting/Picking system
    • Control system
    • Material handling tools
    • Electronics/Car wash machines
Its material handling systems find applications in Food & Beverage industry, Pharmaceutical & Cosmetics industry, Paper & Printing industry, Metal & wood industry, Transport Industry etc. Its solutions are capable of meeting the manufacturing automation and labour saving needs in any organization. With automation of maintenance operations the renowned organization has scaled the next higher level in business. Here, it is remarkable to mention Mr. Hiroshi Geshiro, President and CEO of Daifuku has recently mentioned in an interview that the company has launched a three year business plan taking into account the ever increasing need for automation with a strong emphasis to accelerate digitization.

Problem Statement

Carrying out Preventive maintenance using conventional methods just created a mess with no effective mechanisms to trace service requests and these approaches did not fail to expose their inadequacies when the volume of maintenance work piled up. Managing spares was not easy as an organized approach was not in place to segregate spares, labeling them for unique identification, pull out immediately upon need for quick fixes etc. They lacked a proper solution for Attendance Management, Warranty management, and On site technicians management which resulted in a setback in progress of maintenance management.

Solutions Provided by InnoMaint

InnoMaint provided comprehensive maintenance solutions. It provided the ability to track the current location and the path of travel of a technician besides the information on total kilometer travelled along with an Estimated Time of Arrival. They were required to punch -in while entering a new premises and punch-out at the end of the day. This was especially useful as the technicians may work on different locations each day.
QR codes were associated with spares and assets for unique identification and instant retrieval of all data on the item, in a single simple mobile scan. The CMMS provided a provision for storing spare parts at customer location for faster dispatch.
Digitization of maintenance operations enabled recording of all data pertaining to maintenance on a centralized cloud server and quickly retrieve them on need. This enabled them to perform quick and easier audits, measure & improve the performance of technicians, drive quality & reliability throughout the organization etc. They were able to dispatch technicians after taking into account the current dynamic work load, skills of the technician & proximity to the facility.

Results

   Technician location tracking & travel history for quick task allocation
   Attendance Tracking for ensuring prompt visit of technician to the premises.
   Able to track effective working hours with 5 star ratings.
   Made the best use of warranty of assets and spares.
   Line supervisors can assign tasks for onsite technicians from anywhere.
✔   Improved customer and technician based inventory management

How a chain of retail stores standardized
& tracked maintenance

How PMV Maltings delivered consistent
and increased production

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Innomaint helped PHA realize the benefits of migration from paper work to automation

Innomaint helped PHA realize the benefits of migration from paper work to automation

Pyeong Hwa Automotive(PHA) is a leading manufacturer of automobile door moving systems which form an integral part of vehicles. The key products it manufactures include latching systems, hinges, door products & power systems. PHA was looking for a solution to plan, schedule, organize, prioritize & carry out maintenance tasks in a better way with a good acumen.

The several decade old global company Pyeong Hwa Automotive(PHA) set up its branch in India at Chennai in 1997. Having foreseen the enormous potential in India to become one of the world’s top 5 automotive producing countries, the company grew steadfastly to achieve its present stature with an annual revenue in the range of billions. The company’s main plant at India spans across a vast aggregate area. PHA uses Innomaint for managing the entire maintenance realm of their business.

PyeongHwa Automotives India (P) Ltd.
Industry Automobile
Location India
Founded 1997

Problem Statement

With the rise of maintenance management needs the management felt the pain of tracking the entire maintenance sphere of the business based on the information in conventional files and excel sheets. These approaches proved to be unreliable, ineffective & tedious to follow up. It was then they availed the services of Innomaint to address the shortcomings of traditional methods and to provide the management with tools to measure the performance of individual technicians, gain a visibility of the big picture, gain instant access to data etc.

Solutions Provided by InnoMaint

We installed our Asset Management Software on their server as a perpetual license model. They subscribed for our Enterprise package offering support for unlimited users and full functionality. The technicians and factory staff adapted to Innomaint application pretty quick and found it easy to day-to-day use. Innomaint lifted all communication, location barriers in the form of mobile app, multimedia ticketing system. Features such as QR code scanning, GEO Location tracking along with AWS database hosting earned Innomaint the reputation of a safe & reliable solution provider.

Results

The business data of company is now safe & secure with Innomaint application installed on their servers free from any accidental data loss. PHA now doesn’t fail to schedule planned maintenance at the right time. The automation makes the process well organized. Admin is able to view the scheduled tasks from a central 52 week PPM calendar. No more complex formalities in data access while ensuring the data is accessible only to relevant and right persons..

The manager is made well aware of the spare usage, spare levels in the inventory and have a mechanism to know the current workload of each technician before assigning them with tickets. The technicians are unable to give false statements regarding their location as they are continuously tracked. The reporting is made simple and quantified. Technicians are able to easily access solutions provided to similar issues for the asset, at hand. Such a reuse of knowledge of seniors help in quick resolution of issues apart from eliminating or minimizing training.

The maintenance big picture is depicted in a simple and striking manner in the form of graphs which makes it easy for managers to arrive at well justified and sound decisions. They are notified via messages whenever SLA definitions are violated keeping them in the loop of delayed tasks. They are able to set up reminders for tasks they tend to forget. For all these reasons PHA repose trust in the capabilities of Innomaint.

How Roxy Roller Mills maintained quality throughout entire food supply chain
How a service company managed grid stations with improvement in operations

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How a service company managed grid stations with improvement in operations and first time fixes

How a service company managed grid stations with improvement in operations and first time fixes

Established in 2006 Majees Technical Services (MTS) LLC was founded in 2006 by Mr. Ishrath, an engineering graduate and management professional after gaining few years of work experience, in the Sultanate of Oman. The company which had a humble beginning with just five employees is now 160 employees strong with diversification into various sectors such as Oil & Gas, Energy, Fire & Security, Infrastructure, Transportation and HVAC. The organization has a branch office at Dubai.

The following companies are subsidiaries of MAJEES…

ULIS Oman LLC

Offers services such as underwater maintenance works, inspection and repair and other facets of marine engineering and construction.

Majees Technical Services LLC
Industry Engineering Services
Location Oman
Founded 2006

Gulf Coast International LLC (GCI)

An authorized distributor for Hempel Paints dealing with construction materials and chemicals specializing in tiles & marble fixing.

Problem Statement

Majees was seeking a software to manage all their customer Asset’s – Region wise, Building wise & System wise. It was a pain for the organization to trace and track Preventive maintenance schedules executed at various Grid stations belonging to the customers of MAJEES, including Warranty and AMC Contracts, from heaps of paper and excel sheets. They were seeking for a better solution to organize maintenance and improve overall efficiency of the maintenance business with enhanced visibility.

Their nature of their business involves field work at disparate locations. The customer premises too were vast and hence identification of the asset or job site within the campus was, by itself, a tiresome task. MAJEES mentioned the complexity of tracking technician performance and asset maintenance increased proportionally with the number of geographic locations of clients. Each Facility Manager faced difficulties in generating reports manually on the progress of maintenance activities for submission to C.E.O or Global business heads.

Solutions Provided by InnoMaint

We imported the assets of their customers, successfully, to our digital CMMS solution.

As a step towards betterment of overall maintenance operations using InnoMaint application:

    • Service engineers were able to automate their PPM Schedule Grid Station wise. The Facility Manager or supervisor incharge for maintenance works in a Grid station got greater visibility into the operations & were able to generate quick reports and submit the same to the Global Maintenance Head in minutes.
    • The information on the facilities and assets which were currently under the coverage of AMC for each client was safe and secure in cloud servers & available instantly.
    • The service business was able to provide a good deal of transparency providing customers an Estimated Time of Arrival(ETA) on technician and through the mobile app the customer can track the movement of the technicians through the entire way into their premises.
    • Super Admin was able to gain a big picture of maintenance progress at each customer location in the form of Dashboard and KPI reports
    • MAJEES was able to improve day to day operations by measurement of performance and enhance customer service in Fire & security division.
    • InnoMaint provided Mobile and Web Application for their customers in different regions to map their Assets into InnoMaint, easily track and raise service requests easily from their mobiles.
    • Customer’s GEO address can be identified (Latitude, Longitude) using Innomaint Application.
    • Detail Asset mapping with information on AMC, Warranty, Project name & project codes on the basis of customer, region, from start date to end date were handled using Innomaint with easy and authentic access.

Results

  • The instant retrieval of information on AMC helped facility managers to canvass the extension of AMC packages providing financial security to the company. They were even able to provide quotes with a customized touch for each customer.
  • The Facility Managers were able to automate their Warranty Management deriving utmost benefit from the warranty cards of assets thereby avoiding premature disposal of the asset.
  • Customers were able to provide service requests via mobile app. There was no room for Service Engineers for delay in arrival at customer premises. The service engineers within Geo Fencing circle alone shall attend the customer paving the way for quicker reach.
  • Managers were able to identify the overall picture on maintenance which provided useful information in identification of training requirements and improvement of performance at the field.
  • The organization (MAJEES) was able to retain ISO 9001:2008 Certification by means of consistent quality achieved through automation, auto assignment of tickets, rating of services etc.
Innomaint helped PHA realize the benefits of migration from paper work to automation
How a chain of retail stores standardized & tracked maintenance while on the go 24/7

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How a chain of retail stores standardized & tracked maintenance while on the go 24/7

How a chain of retail stores standardized & tracked maintenance while on the go 24/7

Ranch Market is a supermarket or chain of retail stores in U.S.A serving products including bakery, fruits, vegetable, meat, grocery items etc. They have a good reputation in the market for the wholesome, nutritious and tasty food. They source fresh products from trusted suppliers. Several franchisee’s run the business since 1998 in Indonesia. It provides fresh products catering for high-end and middle-high class customers. To uphold and maintain customer loyalty Ranch Market continues to improve the shopping experience and customer satisfaction.
Ranch Market
Industry Retail Stores
Location Buena Park, California, United States
Founded 1984

Problem Statement

By the early 2020, the Company was operating 48 stores located in several cities in Jakarta, Jabodetabek, Surabaya etc.The management of Ranch Market wished to manage their stores at various locations by themselves. Each Store Manager and supervisor came across difficulties in raising service requests for maintenance of assets in their store. The Supervisor (Civil, Electrical, HVAC) were not in a position to track the technicians for assigned job work orders on a daily basis. They did not have a means to measure the performance at work, time consumed for work, completeness of the fix provided etc.

They wished to have a closer scrutiny on the performance and promptness of service engineers.

Solutions Provided by InnoMaint

    • With the help of InnoMaint AMS Software the Management easily generated and printed QR code and pasted them on assets for easier asset identification, and pulled out complete service history by scanning QR code for best fixes.
    • Mobile application for all their Store Managers & Supervisors to raise service requests instantly.
    • Supervisors were able to assign or reschedule jobs even while away from the store 24×7.
    • Using Geo-Location Tracking the service engineer within Geo Fencing circle attended the store paving the way for quicker resolution.
    • Managers measured the Average Response time, Average Resolve time, SLA compliance etc.
    • Multiple Reports such as Service Request Raised vs completed, Individual work order reports with photo, video along with KPI’s make up for a good analysis of maintenance progress.

Results

   Smooth work handover to a different team or external service contractor.
   Technician’s performance can be rated based on several aspects & KPI metrices.
   Store managers can now establish a benchmark for performance by comparison with other stores after proper authentication.
   Managers were able to carry the power of CMMS in their palm wherever they go.
   Assets or tools can be moved between locations without any deadlocks. With clear visibility.
✔   Knowledge of seniors is available in the form of knowledge base to provide quickest fixes.
✔   Multiple & multi-level reminders and escalations keep important or long pending tasks in the loop of Managers or supervisors.

How a service company managed grid stations with improvement
How PMV Maltings delivered consistent and increased production

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How PMV Maltings delivered consistent and increased production by reducing maintenance backlogs

How PMV Maltings delivered consistent and increased production by reducing maintenance backlogs

Established and incorporated under the Indian Companies Act, PMV Maltings Pvt Ltd. is one of the largest Malting companies in India. The company has a long experience in the field. It is a closely held family owned company by Jains, a business family from the past seven generations. PMV Maltings is an ISO certified organization.

Manufacturing Facilities

Pataudi Plant

The unit is designed and constructed as per state of the art practices and technologies. It is semi-automatic plant fully made of stainless steel. The plant has a capacity to produce 30,000 tons of Barley Malt per annum. As a part of fully automating the operations PMV Maltings subscribed to InnoMaint

PMV Maltings Pvt. Ltd.
Industry Food Industry
Location India
Founded 2004

Kashipur Plant

The second unit is a state of the art, fully- automatic, stainless steel Malting plant located in Uttarakhand. The site has capacity to produce 150,000 tons of Barley Malt per annum.

The company also supplies Roasted Barley / Wheat Malt which can be used by brewers and food companies to impart colour & flavour to their products. The entire malting process – steeping, germination and kiln can be operated in the same boxes, controlled by computer automatically.

The company has a full-fledged laboratory to carry out various testing and product developments by its technically qualified experts in the field of food processing.

Problem Statement

Production cycles were affected during night shifts as monitoring the progress during odd hours was practically very difficult. Generation of reports robbed much of the precious time of Management and those reports were not fully reliable as well. The Management were desperately seeking a ticketing system to standardize and regularize routine maintenance activities. Procuring spares well in advance was not done and Inventory management staff needed to be aware of the closing stock on each transaction and an intimation mechanism on reaching a minimal count so that they can strike a balance between instant availability of spares and unnecessary storage in excess.

Solutions Provided by InnoMaint

With automation of maintenance operations the plant became fully automatic which is the current trend in maintenance management. InnoMaint fully automated their Planned Preventive Maintenance Schedules and addressed the corrective maintenance, as well, in an effective and amicable way.

The management leveraged the Solution Bank feature of InnoMaint available to the service technicians via easy to use & user friendly mobile app which are usually created by senior technicians and approved by Facility Manager. Fixes to common and frequently occurring issues was delivered when the technicians required it providing instant help, on the field.

While keying in the defect statement for posting service requests the CMMS software listed out similar types of defects raised for the asset in the form of autocomplete entries.

All stakeholders were promptly notified for deviations in Service Level Agreements with multiple and multi level remainders and escalation so that the management were able to speed up maintenance work at each and every stage.

They used calibration workflow provided by InnoMaint to calibrate all the measuring instruments in their lab for ensuring the accuracy in measurements.

Results

  The downtime of assets was reduced greatly by 30% even during night shifts.
   InnoMaint brought about an improvement in production of barley by 20 percent by effective maintenance handling and periodic system audit
  The technicians duly attended to auto assigned tasks during all shifts & provided a complete & best fix predominantly in the first attempt.
   The plant derived utmost benefit from their assets by improving Mean Time Between Failures(MTBF) and Mean Time To Repair(MTTR).
   InnoMaint helped in achieving optimum level of spares in the inventories with
✔   Intimation on reaching minimum re-order levels.
✔   Genuine spares were dispatched quickly so that normal working condition was restored at the earliest.
✔   As key stakeholders were brought in the loop of challenging maintenance issues the number of tickets in backlog were greatly reduced
✔   InnoMaint helped them in generating around 30 + customizable reports in few clicks for quick review meetings.
How a chain of retail stores standardized & tracked maintenance while on the go 24/7
How a field service company turned the tables on maintenance

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