PÖTTINGER Landtechnik replaces SAP PM with ISPRO-NG
Optimized maintenance processes thanks to the CMMS isproNG
The successful replacement of SAP PM with isproNG has significantly optimized maintenance processes at PÖTTINGER. Efficient resource planning, user-friendly mobile applications, and modern technologies have greatly improved usability for the 27-member team, enabled a vulnerability analysis, and reduced downtime and maintenance costs.
The in Austria / Grieskirchen - based family business PÖTTINGER was founded in 1871 and has grown steadily ever since. isproNG - a comprehensive maintenance management system- from H&H Systems replaced the previously used SAP PM system. In its modern assembly halls, PÖTTINGER manufactures innovative agricultural machinery such as forage wagons, mowers, plows, and seeders. In the adjacent Technology and Innovation Center (TIZ), these machines are tested under realistic operating conditions.
The Grieskirchen plant is home to one of the most modern loader assembly lines, a unique parts painting facility, and the latest laser cutting machines with automatic warehouse integration. In total, the maintenance team manages over 1,500 assets and pieces of equipment- ranging from production machines and interlinked systems to production aids and industrial trucks- in addition to performing inspections required by inspection logs. In this interview, Reinhard Bachschweller, Head of Maintenance at PÖTTINGER, and Oliver Hofbauer, CEO of H&H Systems, discuss how the implementation of isproNG at the agricultural machinery manufacturer is making maintenance processes more efficient.
The replacement of SAP PM took place over several months in close cooperation between PÖTTINGER and H&H Systems. What were the primary goals of the project?
Bachschweller: The replacement of SAP PM with new maintenance software was motivated by a number of operational and strategic goals. Operationally, the new software was intended to offer simplified administration and order placement, a self-learning system, high user-friendliness and a clear structure, short response times, and optimal spare parts availability. Strategically, the focus was on identifying weak points, increasing the level of planning, continuous improvement, and effective knowledge management. In addition, the software was to support various maintenance strategies, including TPM, condition-based maintenance, preventive maintenance, and failure-related maintenance.
How did the selection process for the new maintenance software work?
Bachschweller: To achieve the set goals, we conducted a comprehensive analysis of the current situation by surveying all stakeholders and defined the resulting requirements. Based on these requirements, we then drew up a corresponding specification sheet. In a multi-stage selection process, the specifications were sent to a large group of CMMS providers. We then invited three providers to give an on-site presentation and submit a quote. After conducting a cost-benefit analysis, H&H Systems emerged as the clear winner with isproNG and was hired to implement the system.
How has the introduction of isproNG changed maintenance personnel and resource planning as well as maintenance planning compared to the previous method?
Bachschweller: Before the introduction of isproNG, both planned and corrective orders were assigned manually by assigning the order ID to the employees and then sent by email, or the orders were printed out and handed over manually. With isproNG, orders can be assigned personally or to workgroups using the “group technician”. Push notifications inform employees on their tablets immediately. If there is free capacity, employees can independently take on tasks from the order tool. This greatly simplifies administration and order placement.
Has this also improved response times?
Bachschweller: The use of the isproNG app has significantly improved user-friendliness and shortened response times through timely bookings via mobile devices. Previously, it was necessary to switch between different systems permanently, which made the handling very complicated. The use of the isproNG app reduces manual effort and error frequency of the real-time order documentation and increases its quality.
Every downtime costs a company money. How does isproNG affect production downtime?
Hofbauer: With isproNG, all necessary information is available on the go at any time, which leads to a significant worktime reduction . Better planning and preparation eliminate search times for documents, spare parts, and tools, which noticeably reduces production downtime.
How does isproNG support the maintenance task documentation?
Hofbauer: Modern auto-ID technologies such as NFC and QR codes further reduce the amount of manual work by making it easier to manage order documentation using a smartphone or tablet, both online and offline.
With several thousand maintenance tasks per year, it is not always easy to keep track of everything. How do you keep track of maintenance activities and assets at PÖTTINGER?
Bachschweller: Interactive live dashboards for predictive maintenance give both, the production managers and the maintenance staff constant insight into the current task status. Live monitoring (or the ability to do so) supports the maintenance team in creating key figures, reports, analyses, and standardizing key figures.
The majority of maintenance activities in companies are corrective. Has isproNG changed this at PÖTTINGER?
Bachschweller: Cost drivers and weak points in the equipment can be identified more quickly and the user-friendly and simplified administration has also already increased the planning level.
And what about recurring maintenance processes?
Hofbauer: Any feedback from maintenance tasks with image and/or video recordings automatically feeds the knowledge database, which is available for later similar maintenance tasks and therefore reduces repair time.
Is the equipment documentation also integrated into this knowledge database?
Hofbauer: All information on the individual assets and equipment is stored in isproNG thus also available on the go at any time.
Spare parts and inventory management always poses challenges for large companies. Has this improved within PÖTTINGER with isproNG?
Bachschweller: isproNG enables the establishment of group-wide and cross-location spare parts management with interfaces to SAP MM. This improves spare parts availability, reduces inventory costs, and increases transparency and planning through cross-plant use of inventories.
Does that mean that other PÖTTINGER locations are also integrated into isproNG?
Hofbauer: All locations, including Vodňany in Czechia and Bernburg in Germany, have already been integrated into the central CMMS isproNG, which enables a high degree of standardization, uniform maintenance processes, and central administration.
The new maintenance software has now been in use for over a year. Have savings and optimization potentials already been achieved?
Bachschweller: The utility analysis, which was carried out one year after the implementation of isproNG, already shows important optimizations and savings in many areas. For example, the reduction of search and work time, simplified administration and, above all, the increase in the degree of planning and technical availability.
Thanks to Mr. Bachschweller for the interview!
Images/Source: Pöttinger Landtechnik GmbH
