Case Study Jamar

Jamar has implemented a mobile production maintenance management system CMMS+EAM 4FACTORY

JAMAR was established in 1994. It is a dynamically developing company, whose products are well-known at home and abroad. The company offers a wide range of food products. Among the most important are: canned vegetables, concentrates, vinegars, spices, food additives, sauces, juices, syrups and fruit preserves. JAMAR currently employs over than two hundred people. The factory works exclusively with professional Polish farmers, who provide the company with the highest quality raw materials.
Plant varieties with the best parameters are used for sowing. The harvests are supervised and controlled by JAMAR’s specialists, who ensure that raw materials for processing meet the requirements of the IFS certificate, are distinguished by the highest quality, and have high taste and nutritional qualities. JAMAR products meet the expectations of even the most demanding consumers.

Implementation goals CMMS+EAM 4FACTORY

Implementing any IT solution without precise expectations and objectives can be compared to making vague resolutions. Before deciding to implement the advanced EAM 4FACTORY (Enterprise Asset Management) tool, JAMAR decided, in the first phase, to set realistic objectives and, together with the software supplier, DSR S.A., to draw up a detailed schedule of the subsequent implementation activities.

The EAM 4FACTORY system should guarantee access to all information on the current status of the machinery. In addition, the software should allow easy access to reports of all events that occur in the area of the entire JAMAR organisation. This includes machinery and equipment in the production halls, as well as the rest of the factory infrastructure, which includes vehicles, facilities and other equipment.

We also expected that, as a manager, I would have better information about the current situation on the production lines, which would enable me to allocate tasks more efficiently to the relevant technicians in my department. We wanted to improve the existing flow of information, especially between the production and technical departments. The main objective was to eliminate phone calls and the verbal communication of information from production operators to the mechanics – Sylwester Szafer Technical and Investment Manager at JAMAR.

Functional requirements

At JAMAR, it is assumed that any failure or other event requiring the intervention of the maintenance service must be immediately signalled in the EAM 4FACTORY system. The main objective of the maintenance service is to react quickly to incoming messages and to take appropriate action as soon as possible after the event has occurred. In this context, it is very important for the company’s employees to be able to independently enter notifications regarding various events that require the intervention of the maintenance department, at any time and from any location. The solution to the above challenges/expectations is the terminal version of the EAM 4FACTORY system. It allows relevant information to be entered in a very fast and intuitive way, which is immediately communicated to the maintenance staff.

Rys. 1 Login screen view in the terminal

Rys. 2 Terminal notification screen view

The number of production kiosks with access to the terminal version is about twenty workstations, used by more than a hundred direct and indirect production employees. A certain obstacle was encountered during the pre-implementation work. During the preliminary interviews, the attitude of the technical staff was often sceptical. They were mainly concerned that they would have to spend most of their time in front of the computer, reporting the required data, when at the same time they had to take action for the next breakdown or preventive work related to periodic inspections. In addition, some managers may have found it too inconvenient to operate another computer system. With these needs in mind, a mobile version of EAM 4FACTORY was used, which is currently installed on the phones of nearly thirty users – Anna Hyra, Leader of EAM 4FACTORY system implementation at JAMAR

Rys. 3 The EAM 4FACTORY mobile application

JAMAR also needed to implement a solution that would allow all the information flowing from the events recorded by the production operators and mechanics on the terminals to be integrated into a single mobile application. This would provide the entire technical department with a single database and a single interface for managing current and planned tasks. The browser-based version is the third tool in the EAM 4FACTORY system. It is the most advanced version, equipped with individual modules: a defined database of resources, registered requests, orders executed by mechanics, a verification module and a reporting module. The latter makes it possible to constantly monitor the cost of maintaining the machines and the quality of the work carried out by the mechanics. At JAMAR, seven users from the maintenance department currently have full access to this information. – Marek Lebiocki Senior Consultant at DSR, EAM 4FACTORY Product Owner

Rys. 4 Operations and administration portal

Once most of the functionality was in place, there was a quiet concern about whether we were properly prepared for launch. Did we anticipate everything? Were we ready for such a big organisational change? We quickly came to a decision: Yes! We are going ahead with the planned implementation schedule. – Anna Hyra

Launching the system

Thanks to our well-planned work, we had enough time to get other users from other departments on board. As we gradually started internal training, the time came to fully implement the system. It was not an easy time for our whole organisation, as we had to change old habits, but in retrospect I can say that we did it very well. Under my supervision, we were able to use the EAM 4FACTORY application on a trial basis for a month, treating it as a transitional period, to finally go live on 02 January 2019. – Anna Hyra

Post-launch

We are now trying to solve problems before they occur through preventive maintenance. In the
EAM 4FACTORY system, we have worked together to create a maintenance plan for machinery and equipment. Importantly, even before implementation, after careful analysis, we created checklists for each type of asset, allowing us to determine the next steps in preventive work. With the functionality of EAM 4FACTORY, we have eliminated the paper versions of key documents previously used and automated the flow of necessary information. Thanks to regular inspection intervals, we are able to largely anticipate problems that can negatively affect the condition of the machines, but also the continuity of the production process. – Sylwester Szafer 

Summary

The support of the software supplier DSR S.A. was very important for us. I can confirm that we received appropriate assistance at every stage of the implementation of the EAM 4FACTORY system. We have already worked with DSR during the implementation of the ERP 4FACTORY system: QAD. As a result, we quickly found a common language.
– Anna Hyra

To sum up, it’s a good idea to show employees how they will benefit from the implementation. For example, a well-defined request that specifies exactly which area of the plant they should go to, the status of the request and what needs to be done. Ultimately, we’d like to be able to see what spare parts are associated with a particular asset, how many are in stock and where they are located. At the moment, we are mainly focusing on prevention and prediction in maintenance, rather than reacting to failures that have already occurred ~ Sylwester Szafer.

Among the many benefits that have been achieved as a result of the joint effort, in addition to the most important, which is the change in the approach and organisation of the work of the maintenance services at JAMAR, the most important is the orderly recording of the machines, tools and other production resources, which currently number 2,400 items. The database of events recorded in EAM 4FACTORY counts almost 25,000 messages since the beginning of its implementation, not only in the case of breakdowns, but also in the case of modifications, adjustments, start-ups, overhauls or anomalies detected or suggestions made by employees. On the other hand, 20,000 preventive orders with checklists of activities to be performed have been completed ~ Marek Lebiocki

Other important benefits of implementing and using EAM 4FACTORY are:

• Full identification of the maintenance department’s work;
• Easier control and management of preventive work;
• Improved efficiency and effectiveness of production resource management;
• Increased productivity of machines and equipment;
• Reduced capital and operating costs;
• Ability to work from anywhere via mobile application;
• Easy scheduling of inspections and maintenance;
• Integrated reports for data analysis;
• Access to relevant additional services;
• Expert support for system implementation and operation;
• Intuitive and easy to use user interface;
• Cyclical software updates;
• Easy and fast implementation.