Afonwen Laundry successfully automates workflows, processes, and procedures using eMaint CMMS software2019-06-11T11:02:26-04:00

Project Description

Afonwen Laundry successfully automates workflows, processes, and procedures using eMaint CMMS software

Afonwen, one of the largest, high-volume laundry and linen providers in the UK, serves nearly 300 hotels and 75,000 hotel bedroom across England and Wales. The British processes more than 1 million linen items a week, with ten technicians keeping more than 130 assets in tip-top shape.

  • Improved machine reliability to ensure timely linen service to almost 300 hotels

  • Gained more accurate measurements of actual asset downtime vs. linen piece output

  • Enabled easy monitoring of PM goal completions and report generation for corporate office

  • Increased ability to detect a failing asset before failure

BACKGROUND

Afonwen Laundry Service is one of the largest high-volume laundry and linen providers in the UK and part of the Johnson Service Group family of brands. The company was founded in 1935 and started as a small linen commercial laundry company. The organization expanded significantly in recent times with the opening of its South Wales laundry center in 2008.

Today, the Cardiff, UK operation processes more than 1 million linen items a week. They provide services to almost 300 hotels and 75,000 hotel bedrooms, operating several locations across England and Wales. Ten technicians work to keep more than 130 assets running. During the high season, the laundry service operates up to 24/7. Equipment includes washers, conveyors, tumble dryers, feeders, steamers, and folding machines.

THE CHALLENGE

Gavin Ward, the Engineering Manager, wanted to make operations more efficient at the Cardiff location by automating workflows, processes, and procedures. The company was using spreadsheets and pen and paper to manage maintenance operations and had recently invested over £1 million in new machinery. Gavin sought out a computer maintenance management system (CMMS) software to help Afonwen better manage its new and older assets, as well as improve operations.

IMPLEMENTATION

The organization chose the eMaint CMMS software for several reasons: its direct association with the Fluke Company and tools, which owns eMaint, and the ability to scale the system across multiple locations.

So far, nine site locations within the Johnson Service Group use eMaint CMMS software. Several locations leveraged the existing data and system set up from the Cardiff location to support their CMMS efforts. By modeling the Cardiff plant, PMs have been standardized at each location when and where it makes sense. Apart from this, individual plants can easily configure PMs to fit their exact needs using the flexible system. The sites across the UK regularly communicate and share eMaint CMMS best practices.

RESULTS

One of Gavin’s goals was to get a more accurate measurement of machine performance. He set an hourly production rate for each asset and created a formula—downtime ÷ by pieces produced per hour. Using the figures, he can now generate a more accurate report showing the total asset downtime per day.

He was also able to justify spending money to replace a critical but poorly operating feeding and folding machine. Using eMaint data, he proved that the downtime and lost productivity warranted replacing it with a new machine.

Additionally, technicians now log in and see a standardized WO procedure, and log out once repairs or PMs have been completed. They also use the system to record observations. If they find an issue, the technician immediately sends an email through the system to the appropriate personnel.

BENEFITS

  • Reduced reactive maintenance by improving PM processes and procedures

  • Identified bad actors based on number of WOs and time spent repairing an asset

  • Tracked labor time to ensure work was being performed efficiently

  • Identified areas requiring capital expenditure; replaced aging equipment thus improving performance and reliability of the plant

Afonwen

“I have to justify maintenance costs every month to our leadership team. I set up KPIs and have a specific PM completion rate to meet. I can use eMaint to create a report showing our corporate office we’re meeting our goal. We are now operating the production facility more strategically and with enhanced reliability and lower downtime, meaning it’s a win-win for the business and its customer base.”

Gavin Ward, Engineering Manager