Clever maintenance

Beverage producers now benefit from more support when servicing their machinery: with immediate effect, KHS ConnectApp Guide includes further functions for even more efficient maintenance management. By integrating bills of materials and introducing dynamic, usage-based maintenance intervals, the application is better attuned to the actual level of system wear. This saves time, conserves resources and helps to optimize spare parts stockkeeping.

KHS ConnectApp Guide was launched as a standalone app in March 2024. Since then, the intuitive digital assistant has brought valuable maintenance expertise straight to the shop floor. The system specifically digitalizes daily CILT tasks, with the CILT acronym standing for the essential routines of cleaning, inspection, lubrication and tightening of components. Where Excel lists or PDFs were used to date, in future the app will proactively remind personnel of all due routines, prompting them through the processes like a task manager.

The further developed KHS ConnectApp Guide is a prime element in KHS’ holistic line concept. Its key benefits include less downtime, on-demand maintenance intervals and more efficient processes for sustainable savings in ongoing operation. As processes are precisely coordinated with one another, the Dortmund systems supplier combines high system availability with a lower total cost of ownership (TCO) throughout the line’s entire life cycle.

Operators also profit from the new features. “The extended app’s intuitive operation in particular received very positive ratings in our pilot projects,” explains Deniz Ulutürk, digital products manager at KHS. “Beverage producers report that training periods are shortened by up to 80%.” 

On-demand maintenance

One major improvement is the app’s new dynamic task function in task control. Until recently, the software managed maintenance tasks according to time, scheduling work at fixed intervals of two days or two weeks, for example – regardless of whether the machine was running at full capacity or was at a standstill. As of now, maintenance intervals are based on the actual number of operating hours. “With on-demand control, we’ve considerably optimized this process,” says Ulutürk. “If a machine is down for a week, components that are only subject to wear during operation don’t need to be inspected unnecessarily.” Dynamic tasks therefore both protect the system and conserve resources.

Real-time analysis

For this to be technically feasible, new KHS systems now leave the factory equipped with an edge device. This compact industrial computer logs production data directly on the machine and sends it through the secure KHS ConnectApp Access link to the cloud. KHS ConnectApp Guide then analyzes the data in real time. When a defined operating hour threshold is reached, the relevant maintenance task automatically pops up on the employee’s mobile device and the production manager’s web platform. This ensures that maintenance steps can be precisely coordinated based on demand throughout the entire line without any link in the production chain being ignored. What’s more, customers can independently add third-party machines and equipment to KHS ConnectApp Guide. 

Full transparency

A further new feature supports maintenance task precision, with complete bills of materials directly uploaded onto the machine at the factory. With this, KHS links digital task management to the technical ‘memory’ of the respective machine.

Direct shop link

In the extended Guide, customers find their lines already preconfigured with all spare parts and their ID numbers. “By including bills of materials, we’re saving customers from having to research,” Ulutürk says. “Employees have access to full, up-to-date maintenance information at all times.” This means fewer queries and a consistently high quality of execution.” To complete this dovetailed process, the app is linked to the KHS Connect shop. Here, any parts needed can be directly identified during maintenance and immediately flagged for procurement.