Bahlsen, a prominent German biscuit manufacturer, is leveraging cutting-edge technology to optimise its production processes and maintenance management. With an impressive output of over 100,000 tons of sweet biscuits annually, which are distributed to more than 80 countries globally, the company has positioned itself as a leader in both Germany and Europe. Central to this optimisation effort is the adoption of IFS Ultimo, an Enterprise Asset Management (EAM) solution, aimed at enhancing efficiency and reducing downtimes across Bahlsen's production facilities.
In February 2023, Bahlsen initiated the implementation of this cloud-based software at its Berlin production site. The move follows a comprehensive strategy where a blueprint for desired maintenance processes was developed and tested. Initially, 24 users engaged with the Standard Asset Management features. A significant aspect of this initiative is the seamless integration of production lines, enabling employees to report equipment failures directly within the system. This feature facilitates immediate resolution of issues as they arise.
Project Manager Aimal Khan, who serves as Digital Manager at Bahlsen, explained the project's objectives, stating, “With IFS Ultimo, we achieve the greatest possible transparency across all sites regarding the condition of our equipment and improved reporting and monitoring of maintenance activities. This data enables us to move from reactive to preventive maintenance and thus reduce downtimes due to unplanned maintenance to a minimum.” The implementation phase in Berlin has set the groundwork for rolling out Ultimo across the company’s other four plants, with plans to extend its use to logistics operations as well.
The deployment of Ultimo allows for effective planning and management of necessary downtimes, ensuring that operators, maintenance personnel, and management have access to a unified dataset. In the longer term, Bahlsen also intends to leverage the integrated Long Term Asset Planning module (LTAP) within IFS Ultimo. By doing so, maintenance staff will be empowered to create long-range budget plans tailored to the condition of their assets and corresponding maintenance costs. This will facilitate informed decision-making regarding maintenance operations, enhancing both effectiveness and cost efficiency.
Heike Roth, Team Lead Inside Sales for IFS Ultimo, lauded the collaboration, stating: “With IFS Ultimo’s cloud-based EAM software, Bahlsen benefits from shared maintenance KPIs that are defined, measured and monitored at group level. Together with the wide range of asset management functions, this maximises productivity and efficiency.” This strategic direction not only highlights Bahlsen’s commitment to maintaining high quality standards but also demonstrates its innovative capacity within the industry.
The capabilities of IFS Ultimo extend beyond basic asset management; its modules for planning, execution, and monitoring of maintenance activities contribute to streamlined operations. The system’s compatibility with intelligent Asset Performance Management (APM) platforms makes it a pivotal choice for Bahlsen as it seeks to enhance operational performance and sustainability.
As a cloud-based solution, IFS Ultimo provides users with the ability to access data from anywhere, utilising both desktop and mobile devices. This flexibility is underscored by the availability of dedicated applications for both Android and iOS, further supporting Bahlsen's goal to implement robust processes for equipment management and maintenance. This advancement in technology signifies a broader trend in the industry, where AI and automation are increasingly becoming integral to business practices and operational efficiency.
Source: Noah Wire Services