Asset Management in Food & Beverage Industries
|Asset Management in Food & Beverage Industries|
Food manufacturing facilities are very large with complex operations using sophisticated machinery and technology that can cost millions. The slightest interruption of one of these processes or issue with one of the machines can cause production to cease, resulting in an absence of products to sell and a serious break in the supply chain. Managing the entire facility and all components inside them effectively is essential to protecting profit margins and maintaining superior customer service.
There is more to plant maintenance, however, than just the production lines, especially in a food manufacturing facility. Bacteria and other contaminants can accumulate on anything and anyone, which can jeopardize the integrity of food. Food processing facilities and the employees that work in them need to follow strict guidelines to prevent compromising the integrity of ingredients, packaging materials, work-in-process and finished goods. This means in addition to regular machine maintenance, maintaining clean facilities, working equipment such as fire extinguishers and other preventative supplies. One major source of bacteria is the actual plant and warehouse flooring. The slightest chip, scratch or crack can be a breeding ground for many organisms that can contaminate food products.
Effective Asset Management
How can a food and beverage manufacturer ensure that every aspect of their facilities are being properly maintained to ensure food safety, efficient production, essential flow of the elements of the supply chain and ultimately deliver great customer service?
The entire facility – the mechanical, physical and human components of the operation – needs to be synchronized, monitored and managed. An effective CMMS maintenance software, can help manufacturers effectively manage physical assets. An asset management process and system that includes design, construction, commissioning, operation, maintenance and replacement of plant, equipment and facilities can assist in optimizing assets and minimize repair costs.
A CMMS system allows management to gain visibility into asset-related costs and projects with a complete analysis of labour, material and contractor expenses. Inventory management achieves the ideal balance between having the right spares on hand and minimizing inventory investment. All aspects of facility management and maintenance, from the physical buildings to the machinery inside, are synchronized to ensure a smooth operation.
Value and Benefits
Profits are critical to food manufacturers. Reducing costs increases profits. The value that food manufacturers can receive from an effective Asset Management system is staggering.
- Reduced Maintenance Expenses
- Increased Production Yield
- Reduced Maintenance Downtime
- Reduced Scrap and Rework
- Reduction in Annual Purchases
- Improved Labour Utilization
- Increased Equipment Service Life
Each of these values represent areas that directly impact profit margins. An effective Enterprise Asset Management solution ensures that a plant is consistently able to meet production requirements at the lowest cost possible, while maintaining the high standards of quality and safety and the ability to become an agile, effective enterprise.
How to improve maintenance in the Food and Beverage Industry – Food and Beverage Industry Requirements
The Food and Beverage industry has unique maintenance needs related to food quality standards, production critical assets, and complex work crews. These needs pose an interesting challenge for maintenance teams striving for more optimized practices.
- Identification of changes in asset health– The identification of changes to asset health, or an impending failure is critical for profit margins in the food and beverage industry. In order to better control their maintenance costs, maintenance teams need the ability to better access and monitor machine data. When maintenance teams can easily identify an asset issue, they can react immediately and swiftly resolve the problem, preventing unexpected and costly breakdowns.
- Strict requirements on equipment performance and food quality standards– The food and beverage industry face multiple industry regulations and food quality standards. The impact of a failure on company revenue can be extreme. Reducing risks and maintaining regulatory standards needs to be at the centre of all maintenance related projects. Asset condition monitoring, as well as effective production control and predictive shutdown systems, are fundamental to safe and secure operations.
- Complex asset connections– Assets in the food and beverage industry are connected by a system of conveyors, belts and fasteners. This adds a level of complexity to maintenance that other industries don’t experience. Maintaining this equipment to keep pace with the rest of the cogs in the food-processing production line requires constant attention and specific technician skills.
- Identify and manage production critical work orders easily – When a critical production asset requires maintenance, it is necessary for the maintenance to be completed as quickly as possible. Additionally, this work cannot take place during critical production periods, unless absolutely necessary. Maintenance teams need the ability to easily plan, schedule, assign, execute, and complete work orders.
- Maximize Uptime of Production Equipment– A food and beverage organization’s production capabilities are highly dependent on the state of its capital assets. Leveraging the availability of key production assets is critical for organizations to meet their quotas. Maintenance teams need to work within these demands to ensure assets are available during critical production periods.
- Continuous improvement with effective reporting – As the saying goes, knowledge is power. When maintenance teams can analyse their maintenance practices, they can improve their planning, scheduling, and execution, and in turn, can optimize their processes. Food and Beverage maintenance teams need access to accurate data to ensure analysis is correct.
- Complex maintenance shifts and work crews– Food and Beverage maintenance planners and schedulers need the ability to handle various groupings of resources for their specific work units. Flexibility to manage crews by craft, team, or a combination is critical for successful planning and scheduling of maintenance tasks.
Why Customers choose Cryotos
- Easy to use, but Enterprise ready, asset management functionality
- Powerful mobile features set for any mobile device or browser based device
- Flexible completion or pre-work criteria to facilitate compliance, including SQF documentation and tracking
- Workflow and notification engine integrated to any aspect of maintenance, new asset deployment, or materials procurement and tracking