Continued from the newsletter:

The Backbone of Operational Excellence

Imagine this: It’s a regular day at the plant. The machinery is humming, the crew is banging through beef sides ahead of schedule, and the cutting, packing and grind lines are running at capacity. Suddenly, the rollstock (thermoformer) machine stops pulling vacuum and is clearly overheating. The entire line grinds to a halt, team members are left idle, and every minute that ticks by costs the plant money—lots of it. This scenario is every plant manager’s nightmare and a stark reminder of why preventive maintenance is crucial.

By regularly inspecting, cleaning, and servicing equipment, plants can avoid these unexpected breakdowns. Preventive maintenance schedules can include everything from simple tasks like lubricating moving parts to more complex ones like replacing worn-out gear boxes or servicing the vacuum pump in your stuffer. Heck, I’ve even seen hard water destroy a rollstock machine from the inside out, causing not only a major loss of revenue due to immediate downtime and repair, but also layoffs due to the extreme lead time of replacement equipment. These routine checks help identify potential issues before they escalate into catastrophic failures. Meat plants measure success in labor dollars per lb, lbs per man hour and other volume-based metrics and downtime is the kryptonite to the meager margins we may have, if any at all. Most of us are operating at a loss on our most average days. 

Unrelenting Commitment to Quality – Do You Have It? Because Guess What – Your Competitors Do!

The quality and safety of meat products are non-negotiable, as we’ve seen in recent recalls due to metal shavings in ground beef or listeria in the Boar’s Head plant. Any lapse in this area can lead to severe consequences, including foodborne illnesses, product recalls, and irreparable damage to a company’s reputation. Equipment that isn’t properly maintained can harbor bacteria, contaminate products, or cause inconsistencies in processing, all of which can compromise food safety and quality.  

Take a common example – rust. Rust itself does not directly harbor foodborne pathogens, but the rough, corroded surfaces of rusted equipment or surfaces can create environments that are more conducive to harboring contaminants. These surfaces are difficult to clean and sanitize, allowing microorganisms to survive and thrive.

As another example, I once had to help a plant strategize a plan to recoup losses after the 25,000 sq ft facility lost power during an extended holiday break. The PMs hadn’t been done on the air handling system, nor had the batteries been replaced in the wireless data-logging temp monitors. They lost over 100 beef carcasses due to the plant heating up to over 90 degrees internally in the summer heat and no calculus utilizing the Tompkins paper could save the meat.

Compliance with Regulations

The meat processing industry is heavily regulated, with strict standards governing everything from hygiene practices to equipment maintenance. Regulatory bodies like the USDA and FDA require plants to adhere to rigorous maintenance schedules and protocols to ensure that equipment is safe and functioning correctly.

Non-compliance can lead to fines, shutdowns, and loss of operating licenses, which can be devastating for a meat business. Preventive maintenance helps plants stay compliant by ensuring that all equipment meets regulatory standards and is in good working condition. Regular audits and inspections (FSAs, SQF Audits, etc) become less daunting when a plant has a solid preventive maintenance program in place.

Cost Savings in the Long Run

While some might view preventive maintenance as an added expense, it’s important to look at the bigger picture. The costs associated with reactive maintenance—waiting until something breaks before fixing it—are often much higher than the costs of preventive maintenance. Unplanned downtime, emergency repairs, overtime pay, and production losses can quickly add up.

Here’s a quote that I once heard from an old timer, and it’s always stuck with me:

Business owner: ‘What if we spend all this money on prevention, and nothing ever happens? It’ll be a waste of money’

Plant Manager: ‘What if we don’t spend the time and money and breaks do happen. Then we’ll be spending 10x to fix it and losing another 5x in downtime’. 

By investing in PM, plants can avoid these unexpected costs and extend the lifespan of their equipment. Regular maintenance reduces the likelihood of major repairs, allowing plants to get the most out of their machinery. It’s a classic case of spending a little now to save a lot later.

Boosting Employee Morale and Safety

Equipment isn’t the only thing at risk in a meat processing plant—employee safety is also a major concern. Malfunctioning machinery can pose serious hazards to team members, leading to injuries or even fatalities. PM ensures that all equipment operates safely, reducing the risk of accidents and creating a safer work environment. When safety features or guards are allowed to break and not be replaced, that’s when major injuries happen. 

Moreover, when equipment runs smoothly, team members can perform their tasks more efficiently and with less stress. They’re not constantly dealing with breakdowns or trying to work around malfunctioning machinery. This not only boosts productivity but also improves employee morale. team members who feel safe and supported are more likely to be engaged and satisfied with their jobs, leading to a more positive workplace culture. There’s nothing that will erode a team’s morale and confidence in the organization they work for than watching the environment degrade without any visible dedication to improvement by ownership.

Building a Culture of Responsibility

Implementing a robust preventive maintenance program goes beyond just taking care of equipment; it fosters a culture of responsibility and care within the organization. When everyone from the owners to the line crew understands the importance of timely upkeep, it creates a sense of shared responsibility. Team members become more vigilant in reporting issues, taking care of the machinery they work with, and understanding how their actions contribute to the overall success of the plant.

This culture of responsibility can also extend to other areas of the business, leading to improved processes, better communication, and a more cohesive team. It’s a ripple effect that starts with something as simple as tightening a bolt or checking a temperature gauge but can have far-reaching impacts on the entire organization.

Conclusion: An Investment in Success

Preventive maintenance in a processing plant isn’t just about keeping machines running; it’s about safeguarding the entire operation. From ensuring product quality and safety to staying compliant with regulations, saving costs, and boosting employee morale, the benefits of preventive maintenance are clear. It’s an investment in the plant’s success, one that pays dividends in the form of smoother operations, higher quality products, and a safer, more efficient workplace.

In the end, preventive maintenance is more than just a strategy—it’s a mindset. It’s about thinking ahead, planning for the unexpected, and taking proactive steps to ensure that the heart of the plant—the machinery and the people who operate it—continues to beat strong.