Kayempee Foods
Achieving measurable improvements in uptime and maintenance costs with Dovient.
Industry Context
Food production equipment typically runs 16 to 24 hours a day. Unplanned stops do not just cost repair time. They risk batch spoilage, missed dispatch windows, and compliance issues with food safety auditors. Maintenance teams in food manufacturing face the added challenge of hygiene-critical environments where cleaning schedules, temperature controls, and equipment sanitization all intersect with maintenance routines. Keeping production lines running reliably is not optional. It is directly tied to product quality, shelf life, and regulatory standing.
The Goal
Kayempee Foods operates food production lines where equipment reliability directly affects output quality and delivery commitments. Their facility runs long shifts, and the production environment demands that mixers, ovens, packaging lines, and conveyors stay operational with minimal interruption. Any unplanned stop on a production line can delay an entire batch, and in food manufacturing, delays often mean waste.
The maintenance team was looking to move from a largely reactive approach to a more structured, planned way of managing equipment upkeep. They wanted visibility into what maintenance was due, what had been completed, and where recurring problems were showing up. The goal was not to overhaul everything overnight, but to build a system that the team could rely on daily.
Specifically, they were targeting a measurable reduction in unplanned downtime, better control over maintenance spending, and a preventive maintenance routine that would also support their food safety audit requirements. PM compliance matters in this industry because auditors want to see that hygiene-critical equipment is maintained on schedule, with records to prove it.
The Approach
- Implemented Dovient as the central maintenance management platform for the facility, starting with a full asset registry covering production lines, packaging equipment, ovens, mixers, and conveyors.
- Set up preventive maintenance schedules for critical production equipment, with frequencies aligned to manufacturer recommendations and the facility's operating hours.
- Configured the PM module to support food safety audit needs, ensuring that hygiene-critical equipment had documented maintenance records with timestamps and completion notes.
- Enabled real-time work order tracking so the maintenance team could prioritize and close tasks efficiently, with SOPs attached to each work order for consistent execution.
- Rolled out in a phased approach: production-critical equipment first (mixers, ovens, packaging lines), then supporting assets (HVAC, compressors, utilities) in the second phase.
- Trained the maintenance team on the mobile app so technicians could receive assignments, log updates, and close work orders from the production floor without walking back to a desktop.
- Activated spare parts tracking to link commonly needed parts to specific equipment, reducing the time spent searching for the right replacement during a repair.
- Used downtime and cost analytics to identify recurring failure patterns and measure progress over time, giving the maintenance manager clear data for weekly reviews.
The Outcome
Timeline
Reduction in unplanned downtime
Lower maintenance costs
Within 90 days of going live, Kayempee Foods saw a 35% reduction in unplanned downtime and cut maintenance costs by 28%. Their maintenance team now operates with clear visibility into equipment health and upcoming tasks. Production line stoppages that used to cascade into missed dispatch windows are now caught earlier, and the team spends less time on emergency repairs because preventive schedules are running consistently. The maintenance manager has weekly analytics to review with the operations team, making it easier to spot trends and allocate resources.
What Changed Day to Day
- Technicians now open the app at the start of their shift, see their assigned work orders for the day, and have SOPs attached to each one. There is no ambiguity about what needs to be done or how to do it.
- PM schedules run automatically. The team gets notified before tasks are due, so nothing slips through the cracks. The maintenance manager no longer needs to manually track what is overdue on a spreadsheet.
- When a breakdown does happen, the team logs it with a root cause and resolution. Over time, patterns become visible in the analytics, and recurring problems get addressed at the source rather than patched repeatedly.
- Food safety audits are simpler. When auditors ask for maintenance records on hygiene-critical equipment, the team pulls up the full history in Dovient instead of searching through paper logs or scattered files.
“Reduced unplanned downtime by 35% and cut maintenance costs by 28% within 90 days.
Dovient Features Used
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