The KHS Group is giving beverage producers more help with the servicing of their machines. Thanks to the addition of various new functions, KHS ConnectApp Guide now makes maintenance management even more efficient by integrating bills of materials and introducing dynamic, usage-dependent maintenance intervals, the application is better attuned to the actual level of system wear. This saves time, conserves resources, and optimizes spare parts stock-keeping.
Since its launch in March 2024, the standalone app and intuitive digital assistant KHS ConnectApp Guide has brought valuable maintenance expertise straight to the shop floor. The system specifically digitalizes daily CILT tasks, namely essential routines in cleaning, inspection, lubrication and tightening of components. In place of the former Excel lists or PDFs, the app now proactively reminds personnel of all due routines, prompting them through the processes like a task manager. The app thus considerably helps to maintain line availability in the long term.
The further development of KHS ConnectApp Guide has yielded key added value: a reduction in the total cost of ownership (TCO). Thanks to less downtime, on-demand maintenance intervals and more efficient processes, users benefit from sustainable savings in ongoing operation. This new digital feature is a prime element in KHS’ holistic line concept. With processes precisely coordinated with one another, the turnkey supplier from Dortmund, Germany, gives its customers high system availability plus optimized overall costs throughout the line’s entire life cycle. “The app’s intuitive operation received very positive ratings in our pilot projects,” says Deniz Ulutürk, digital products manager at KHS. “Beverage producers reported on training periods being shortened by up to 80%.”
Maintenance on demand, not according to schedule
One major improvement in the latest version of the app is that task control has been radically extended. 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. With the app’s new dynamic task function, maintenance is now accurately based on the actual number of operating hours. “Time-based planning has established itself as standard, yet demand-based management considerably further optimizes this process,” explains 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.
This is technically facilitated by the seamless interaction of the app components. 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 cloud link to the system. KHS ConnectApp Guide then analyzes this data in real time. If 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 and that no link in the production chain is ignored. Customers can also independently add third-party machines and equipment to their system.
Full transparency: digital bills of materials database
Maintenance task precision is supplemented by a further new feature: complete bills of materials are directly uploaded onto the machine at the factory. With this, KHS links digital task management to the technical ‘memory’ of the respective machine.
Customers receive their lines preconfigured with all spare parts and their ID numbers. “By including bills of materials, we’re saving customers from having to re search,” Ulutürk says. “With BOMs, employees have access to full, up-to-date maintenance information at all times. This means fewer queries and a highly reproducible quality of execution.” To complete this dovetailed process, the app is directly linked to the KHS Connect shop. Any parts needed can thus be directly identified during maintenance and immediately flagged for procurement.
