The path towards planned preventative maintenance is well underway at Sundown Products. The company is a well-established manufacturer serving farmers and other customers with products including high quality cattle feed, horse, and poultry bedding. Its 3-acre production facility in Huntingdon operates 24 hours a day, 7 days a week, turning straw into Nutritionally Improved Straw (NIS) bovine feed, smart bedding for poultry farming, and sweet-smelling horse bedding which received a Royal Warrant in 2002.
Enabling planned preventative maintenance management
Sundown Products MD David Cubitt decided to install ShireSystem Computerised Maintenance Management Software (CMMS) to improve plant insight and support continuous improvement in its manufacturing process. Increased focus on excellence has already driven a 30% increase in productivity and prolonged uptime in the past year, and it has been directly aided by an improved ability to plan maintenance activity.
Chief Engineer Mark Robertson explains: “If the plant stops suddenly and the system is full it [the product] will solidify incredibly quickly. If that happens, we have to dig it all out by hand. Now ShireSystem will flag up every morning anything that is about to wear out and needs changing, and I have a list of tasks for the day.”
“ShireSystem will flag up every morning anything that is about to wear out and needs changing, and I have a list of tasks for the day.”
Mark Robertson – Chief Engineer, Sundown Products
Improved visibility aids budgeting and resource management
The ability to see what is ahead in order to budget better for maintenance and manage the inventory of spares and consumables are further advantages. Mark recognised these, saying: “Being able to see from the software what I need to do over the next six months means I can plan a comprehensive budget of what everything is going to cost me. In the past, I had no idea because I didn’t know what might go wrong, but now I can budget for critical spares, for consumables, and for my labour needs.”
Production confidence boost for growth
Working with a Computerised Maintenance Management System to help start planned preventative maintenance has given Sundown Products the confidence to actively grow production and run the plant around the clock to fulfil orders. As Mark comments: “We’ve had to run at maximum to fulfil the products on the order book recently – but of course it all uses power. The pelleting plant uses the most electricity – it takes 700 amps per press – while the baling process uses a lot less power. With the increased confidence, we can now run the pellet plant at night, which means we pay half the price of electricity that we would during the day.”
Want to know more? Read the full Sundown Products Case Study about Planned Preventative Maintenance in manufacturing.
The ShireSystem CMMS is one of the UK’s leading maintenance management software solutions. It has helped many of our customers gain improved asset visibility and move towards planned preventative maintenance. Discover ShireSystem CMMS