Case Study: Perfetti Van Melle

Background

Perfetti Van Melle required an Asset Management System to provide them with a global standard, that could be adopted to their requirements and can follow technological developments.

Project

MACS delivered the IBM Maximo solution to PVM. The location PVM Breda in Netherlands was the first site to go live followed by the sites Weert and Sittard – all in the Netherlands.

MACS Challenge

• Providing the IBM Maximo solution for three Dutch sites that also can be used for other manufacturing sites worldwide.
• Deliver an Asset Management solution to enable Perfetti Van Melle to follow technological developments.
• Implement IBM Maximo at three production sites in the Netherlands.

Maximo Sweetens Labour

It could be a riddle: “What have the US, Germany, The Netherlands, Denmark, United Kingdom and China in common?” The answers is not something you immediately think of. All these countries are mentioned in lists of countries with the highest candy consumption.

It’s no wonder we all love candy; candy has been made since the 5th century. International candy and sweets producer Perfetti Van Melle (PVM) has a slightly shorter history. Nevertheless the company has been successfully producing sweets since the beginning of the last century. PVM with its original root in Italy (Perfetti) and The Netherlands (Van Melle), keeps growing and evolving.

Today PVM produces sweets from 35 factories worldwide. These factories produce the world renowned brands such as Mentos, Chupa Chups and many other sweets in different regions across the globe. 

John Boeren, Project Manager Maximo at PVM in Breda highlights how preferences in candies vary widely in each culture. “In Breda we produce 38 flavours of Mentos and only 7 flavours are made for the Dutch market.” John Boeren has been working for PVM since 2000. In 2016 he started as a project manager for the implementation of Maximo at the three sites in The Netherlands; Breda, Sittard en Weert.

IBM Maximo: User Friendly and Flexible

In 2013 PVM decided to select IBM Maximo Asset Management for the maintenance of their production lines. “PVM Breda used to work with another product. It did not give us the flexibility we, as Maintenance, needed for the different factories. “, says John Boeren. “Additionally, some of our smaller production facilities were still working with Excel.” The decision to switch to a standard maintenance management software was fully supported and suggested at C-level within PVM. “Globally PVM’s aim is uniform maintenance; for reports and analysis.” They decided to select IBM Maximo Asset Management.

“IBM Maximo is user-friendly, easy to navigate and can be customised. Maximo is also continuously developing which matches the developments within our company.”, states John Boeren. IBM Maximo easily allows PVM to use it worldwide, supporting the languages of the different PVM locations.

One Blueprint for all Locations

PVM Breda was the first site MACS implemented IBM Maximo. In this plant PVM employs approximately 700 employees. A large part of these employees are part of the technical department consisting of 80 technicians and 12 managers and engineers. Most of them work directly with IBM Maximo Asset Management. “With Maximo we manage the maintenance of our production lines. Preventative maintenance , interruptions, procurement, maintenance contracts and stock of our 8000 spare parts it is all managed in IBM Maximo”. During the implementation process it was essential that PVM took a step backwards to make the best use of IBM Maximo Asset Management. “We looked accurately at our enIre organisation, mapping our entire plant. From how the machines are built up, how the machines are distributed across the plant, procurement processes, roles, to the permission and the access a person has within the system. A task that takes an enormous amount of energy, time and labour. Mainly also because employees need to adapt to change in their current situation.”, describes John Boeren.

PVM plan to roll out of IBM Maximo extensively. Their approach serves as a roadmap and protocol for the roll out in The Netherlands, and other locations outside The Netherlands. John Boeren is project manager, point of contact and advisor for IBM Maximo within PVM Netherlands. His colleague Jacco van Gils is the Maximo specialist who delivers all the modifications needed for the use of Maximo and the roll out of IBM Maximo. 

“The MACS team is our sound board and deliver feedback when needed. For each location you need to have discussions with different departments to gain knowledge and insights about the plant and the processes. The technicians play an important role in this process and the discussions. Finally, we have a flowchart of all people, processes, roles and jobs that can be configured in IBM Maximo”, states John Boeren. Based on his experiences and knowledge John Boeren provides IBM Maximo training at the other locations in The Netherlands and works consultative for the the plants abroad.

The Return of IBM Maximo

The return of investment of IBM Maximo is already clearly visible in different areas and departments. “PVM has more insights in maintenance and the work. There is a better follow up of activities resulting in motivated people that have a hight labour productivity. Information is easier to find when needed. Finally we have a better overview of what the financial return of our maintenance.”

A System for the Future

Go for the max with MACS and IBM Maximo the next step being made is to upgrade all locations to the latest version of IBM Maximo. Followed by the ‘Go Live’ of the site in Sittard.“PVM is an organisation that is always aiming for the highest standards within the organisation. That applies to the people, the machines and also for IBM Maximo. Together with MACS we analyse how we can optimise and expand the use of Maximo. We, MACS and Maximo will continue to follow the technological developments to stay ahead of our competition.”