Automation
TECH FLASH

CMMS simplifies maintenance management and regulatory reporting

August 28, 2012
KEYWORDS CMMS / FSMA / maintenance / PM / software
/ Print / Reprints /
ShareMore
/ Text Size+
Romark Logistics, Hazleton, PA
Aerial view of Romark's 522,000-sq.-ft. warehouse. Source: Romark Logistics.

With ever-increasing demands for accountability throughout the supply chain to ensure food safety—as well as the recordkeeping requirements of the Food Safety Modernization Act and the potentially devastating impact of product loss—maintenance of a multi-million dollar refrigerated facility is of prime importance. To meet these demands at its Hazleton, PA warehouse, Romark Logistics, a third-party logistics provider, chose a computerized maintenance management system (CMMS) to improve maintenance operations, record recovery and retention, and simplify regulatory compliance.

Ryan Ziegler, director of facilities & sustainability management at Romark’s 522,000-sq.-ft. warehouse in northeastern Pennsylvania, and his staff of 10 are tasked with keeping temperatures and relative humidity steady in 40°F and 70°F rooms designed to store a large variety of food and confectionery products.

Romark Logistics ammonia compressors
Ammonia compressor room is monitored by Bigfoot CMMS software, which automatically schedules PM on a regular basis. Source: Romark Logistics.

Ziegler also is responsible for sustainability and capital projects, security, pest control and sanitation in addition to safety, product loss prevention, risk reduction, environmental protection and compliance with federal agencies. Ziegler manages multiple outside contractors who may enter the facility to work on hundreds of assets that run the refrigeration system, material handling equipment, HVACs, lighting, fire systems and the 64 loading docks.

Given the complexity of his responsibilities, Ziegler needed a CMMS to replace paper records, track repairs and/or plan preventative maintenance (PM) tasks. “We had stacks of paperwork orders and PM logs,” he recalls. “Before CMMS, if we handled a repair internally, we’d make the repair and rely on email to notify everyone when the system was back in service, but at no time, was this repair history being organized or connected to the asset.

“And if an outside contractor made the repair, the technician would leave a paper work-order receipt, and I would scan the receipt into the abyss,” says Ziegler. “All of our scanned documents were in a server somewhere. It was impossible to retrieve past repair information to tracks costs.” Based on the value of Romark’s assets, there was a driving need for uptime and record retention as well as better facility planning.

Romark chose Bigfoot CMMS, which according to Ziegler, yielded an ROI from the first auto-generated work order. A PM schedule provided by Bigfoot CMMS helps Ziegler’s team stay ahead of maintenance problems before they occur—unlike the old system of using a three-ring binder to keep track of PM tasks.

“There was no trigger to alert us when it was time to check on maintenance tasks that had to be done and when we needed to do them,” says Ziegler. “We’d have to go through the binder to see what we had to check, or we’d be busy and miss pending PMs. It was an inadequate system.”

Ziegler’s staff and outside contractors also use the new CMMS to instantly call up the total repair history on any asset in the facility. This readily available history saves time and money.

“Without Bigfoot, it could take us months to recover the paperwork on a particular asset. But now, we can pull up a report that tracks our PM activities and shows we’re on top of things and adhering to the requirements of every asset. We’re saving thousands of dollars a year by eliminating reactive maintenance and avoiding potential problems that could lead to devastating losses.”

Because the maintenance management program has proven so useful to his staff, Ziegler says his company plans to incorporate Bigfoot CMMS into the operations of Romark’s warehouses throughout the US—in locations from southern Florida to southern California. “My goal is to maintain and improve the value of all of our assets throughout the company,” says Ziegler. “We want to take great care of our assets, the same way we take great care of our long-term relationships with our customers.”

For more information, visit Bigfoot's website.

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

Fabulous Food Plant: Paramount Citrus

Learn more about this fabulous food plant in Food Engineering's article, found here.

Podcasts

Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

THE MAGAZINE

Food Engineering Magazine

Food engineering magazine 2014 april cover

2014 April

Catch a preview of the Powder and Bulk Show in this April 2014 edition of Food Engineering. Also, be sure to check out a coffee stick making a real stir and a major advancement in the the pet food industry.
Table Of Contents Subscribe

THE FOOD ENGINEERING STORE

Food-Authentication-Flyer-(.gif
Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

Food Master

Food Master Cover 2014Food Master 2014 is now available!

 

Where the buying process begins in the food and beverage manufacturing market. 

Visit www.foodmaster.com to learn more.

STAY CONNECTED

FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.pnglinkedin_40px.png