Dave's Killer Bread Case Study

Customer Since: 2011 | Industry: Food Processing
Improved Regulatory Compliance
With SQF, FDA, USDA & EPA
Achieved 70% Decrease
In Reactive Work Orders
Achieved 140% Increase
In Proactive Work Orders

Dave's Killer Bread (DKB) Tracks KPIs to Justify Maintenance Dollars

Dave’s Killer Bread (DKB) is a leading provider of organic whole-grain bread. Prior to implementing eMaint CMMS, parts or inventory were not tracked, purchase orders were not completed, and DKB’s PM system was non-existent. With eMaint, DKB could accomplish all of this and was able to justify staffing and equipment needs by tracking KPIs. In addition, DKB could create a safer work environment by tracking “avoidable damage” work orders.

BACKGROUND

Based in Milwaukie, Oregon, Dave’s Killer Bread (DKB) is a leading provider of organic whole-grain bread. What started as a small neighborhood business has grown into the largest organic bakery in North America, with its products now available in major retail stores including New Seasons, Whole Foods and Fred Meyer. Maintenance Manager/Planner Robert Hale, and his team of 14 technicians, manage maintenance for the bakery and manufacturing plant.

THE CHALLENGE

In just five years, the company grew from 30 employees to 300 employees, so keeping up with maintenance and regulatory compliance became increasingly difficult. Prior to implementing eMaint CMMS, the maintenance team was not tracking parts or inventory, not completing purchase orders, and their preventive maintenance (PM) system was non-existent. In an effort to more effectively manage maintenance for their growing business, the DKB team decided to implement eMaint. Hale was hired, with 15 years of prior CMMS experience, to help set up the system.

IMPLEMENTATION

In only two weeks, Hale was able to get all necessary data into the system, train the staff, and get fully implemented. “When I first saw the interface of eMaint, I fell in love,” Hale explains. “It was simple and user friendly.” The DKB maintenance, accounting and finance teams use eMaint to generate PM tasks, manage reactive and proactive work orders, generate regulatory compliance documentation, submit work requests, purchase parts and track labor and inventory.

Effectively tracking key performance indicators (KPIs) allowed DKB to get the data they needed to justify their requests. In realizing that technicians were spending too much time on reactive work orders and too little time on preventive work orders, DKB was able to justify the need for additional technicians, along with the need for new equipment in some cases. Additionally, tracking “avoidable damage” work orders, DKB helped technicians understand that their actions have consequences, which resulted in a safer work environment.

BENEFITS
  • Justified staffing and equipment needs by tracking KPIs
  • Decreased reactive work orders by 75% and increased the amount of proactive work orders by 140%
  • Created safer work environment by tracking “avoidable damage” work orders
  • Improved regulatory compliance by providing detailed documentation for Safe Quality Food (SQF), Food and Drug Administration (FDA), United States Department of Agriculture (USDA), Environmental Protection Agency (EPA), and more
  • Improved parts replenishment process through the ability to generate purchase orders

“There is nothing we cannot track on eMaint CMMS, and there is no better way to improve manufacturing than with a CMMS.”

Robert H., Maintenance Manager/Planner, Dave's Killer Bread
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