Challenge: Maintenance

Professional maintenance is the key to preserving the value of machinery and equipment. However, integrating this vital task into daily production schedules is a major challenge for manufacturers in a world of high capacity utilization, frequent brand changes and ambitious quality, efficiency and cost targets. Customized maintenance from the Hauni Group offers optimized, tailor-made solutions.

If production planners had their way, factories would run at full speed every day in multiple shifts to deliver the required output. And rapid brand changes would be available whenever necessary to cover unexpected peaks in demand. Guaranteeing reliable production capacity is certainly a top priority.

Yet, at the same time, technicians need time to carry out regular maintenance – vital for sustaining a high level of performance and avoiding breakdowns. This apparent conflict between the demands of production and maintenance is only superficial though. A closer look tells a different story. "Many manufacturers face considerable fluctuations in demand, so the planning and organization of maintenance is very important. Minimizing unscheduled downtime and planning production standstills in advance allows them to boost both plant availability and performance – even though there may be an initial increase in planned downtime," says Maciej Nowak, Head of Service Sales at Hauni. "Our job is to work together with customers and develop solutions that find the perfect balance between maintenance and production schedules." 


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57% reduction in downtime thanks to our One Shift Maintenance.

Maciej Nowak

Head of Service Sales

Customized maintenance


Flexible, tailor-made maintenance programs are at the core of these solutions. "Flexibility has many different faces. For example, the days of either strictly preventive or completely reactive maintenance are long gone. Today, we aim to achieve the optimum balance our customers need to meet their objectives. We do this by combining preventive, reactive and condition-dependent work on the various system components. Bespoke concepts like these put the customer's goals at the very heart of our thinking.

We design the maintenance concepts in partnership with the responsible persons at the company. They operate the machines under the specific production conditions every day, so it is only natural to base the solution on their experience," says Leif Schierbecker, Group Manager Customer Asset & Maintenance Management at Hauni. "We take our time, find the optimum distribution of the individual maintenance intervals and tailor them accordingly."

Maintenance dilemma: Increasing production pressure often causes maintenance to be delayed or not completed. This inevitably leads to serious problems such as disruptions, quality deficiencies, declining performance and thus further increasing production pressure.

This also clarifies requirements relating to supplies of spare parts, the use of replacement modules and the scope of the hands-on support required from Hauni experts. "Concepts like these allow us to plan the unplannable in production environments," explains Schierbecker. "And timely maintenance performed in accordance with a strict schedule wastes a lot less valuable production time than a sudden stoppage – followed by troubleshooting and, possibly, waiting for an expert or spare part to arrive." Moreover, a good concept will often combine elements of maintenance, modernization, value retention and production optimization. This allows customers to merge modern ideas regarding digital technology with traditional efficiency consulting.


57 percent less machine downtime


Hauni has also developed a new service specifically to offer significant reductions in downtime – especially for plants that are operating continuously at high capacity utilization. "Our One Shift Maintenance service requires just a single shift of scheduled downtime and is always performed after 500 hours of production," says Nowak. "We developed this idea because nobody wants to take an intensively utilized machine out of production for 20 shifts or longer." The results are impressive: based on 10,000 hours of operating time, One Shift Maintenance on a PROTOS-M5 cuts scheduled downtime from 372 to 160 hours. In the past, major maintenance interventions were carried out at fixed intervals of approx. 3,000 production hours. This made the machine unavailable for 16-108 hours. With One Shift Maintenance, Hauni divides these large, preventive interventions into smaller portions and distributes them across a number of slots, which are scheduled every 500 production hours. With only a few exceptions, these scheduled standstills are shorter than one shift.

Under the One Shift Maintenance approach, tasks usually associated with preventive maintenance are often condition-based and integrated into maintenance intervals which do not require the full eight hours. Since 500 production hours often correspond to a one-month cycle, maintenance is now much more continuous than would otherwise be the case.

One Shift Maintenance has also led to a large proportion of maintenance work being performed offline while the link-up is producing again. "Plug-and-play modules significantly reduce downtime. Worn parts from the exchanged subassembly are replaced in the customer’s workshop or at Hauni. The module can then be installed during the next service," explains Nowak. "With this concept, customers can either maintain their own stock of replacement modules or lease the corresponding subassemblies from Hauni. And if a customer decides to standardize the plug-and-play modules it uses across multiple lines, this can generate even greater advantages in terms of costs and complexity."


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Customized maintenance - Carefully coordinated production and maintenance objectives lead to the best possible results: needs-based maintenance work performed at the ideal time prevents unscheduled downtimes and safeguards production efficiency.

Enhanced efficiency due to minimal downtime and vendor managed inventory


Hauni also uses the concept as part of its Asset Protection Program (APP). "This is part of our full-service maintenance package that ensures our customers’ machines keep running efficiently on pre-determined KPIs," explains service expert Hinz. "Customers can significantly increase their production efficiency using these service packages, which are tailored to their operational needs." For this, Hauni’s Technical Customer Service employees are permanently stationed at the customer’s site and handle all the relevant tasks professionally and competently – including regular, condition-based and time-saving maintenance as well as the quick production start, back to high level production.

"In addition to cost savings – through reduced stocks of spare parts, predictable service rates, reduced operational costs and the transfer of know-how from Hauni technicians – the APP offers many other benefits," says Hinz. "These include a lower risk of lost production, due to the immediate availability of all relevant parts for production and maintenance, the permanent presence of a Hauni expert and scheduled maintenance intervals.

So APP really does increase both uptime and output. Overall, it enables customers to boost performance and production security." For Nowak, services like the APP or One Shift Maintenance – with their strict focus on individual customer requirements – represent the future of maintenance. "Concepts like these solve the conflict between maintenance and production pressures. The result is much more harmonious. Customized maintenance keeps equipment performing at a high level and minimizes unscheduled downtime – the impact is immediate but lasting: optimally maintained machines last longer and operate much more efficiently without unforeseen stops or problems."

Customers can significantly increase their production efficiency using these service packages.

Katharina Hinz

President of Hauni Richmond