Loading
myRockwellAutomation
Careers
Investors
PartnerNetwork Portal
Contact Us
Popular Resources
Compatibility & Downloads (PCDC) Knowledgebase Literature Library Lifecycle Status Learning+ Training Portal
 
Product Management
Asset Management (RAAMP) Installed Base Evaluation (IBE) My Equipment Self-Service Product Registration Repairs Service Contracts & Tickets Software Activation Software Subscriptions Sustainability Dashboard
 
Product Configuration and Selection
Advisor Bill of Materials CrossWorks Integrated Architecture Builder Product Catalog ProposalWorks Proposal Builder ProposalWorks Standards Builder Safety Automation Builder
 

 

View All Tools →

InformationInformation
This content is not available in your selected language.
Rockwell Automation logo
Products
Hardware
What's New in Hardware
Circuit & Load Protection Condition Monitoring Connection Devices Distributed Control Systems Drives Energy Monitoring Human Machine Interface (HMI) Independent Cart Technology Industrial Computers & Monitors Industrial Control Products Input/Output Modules Lighting Control
Motion Control Motor Control Network Security & Infrastructure Packaged Solutions Power Supplies Programmable Controllers Push Buttons & Signaling Devices Relays & Timers Safety Instrumented Systems Safety Products Sensors & Switches Signal Interface
Software
What's New in Software
Cloud Software
 
Design
Studio 5000 FactoryTalk Logix Echo Emulate3D Digital Twin Arena Simulation FactoryTalk Design Studio FactoryTalk Twin Studio FactoryTalk Vault
 
Analytics & Data
FactoryTalk Historian FactoryTalk Analytics FactoryTalk Analytics LogixAI FactoryTalk DataMosaix FactoryTalk Energy Manager Thingworx IIoT FactoryTalk Transaction Manager FactoryTalk Edge Manager Model Predictive Control
HMI
FactoryTalk View FactoryTalk Optix
 
MES
Plex MES FactoryTalk ProductionCentre FactoryTalk PharmaSuite Plex MES for Food & Beverage FactoryTalk CPGSuite Plex Quality Management System Plex Enterprise Resource Planning Plex Asset Performance Management Plex Production Monitoring Finite Scheduler FactoryTalk EIHub
 
Performance Monitoring
FactoryTalk Metrics OEE
 
Thin Client Management
ThinManager
Maintenance
Fiix CMMS FactoryTalk Analytics GuardianAI FactoryTalk AssetCentre FactoryTalk Remote Access FactoryTalk Network Manager Emonitor
 
Process
PlantPAx FactoryTalk Batch
 
Industrial Communications
FactoryTalk Linx
 
XR/Augmented Reality
Vuforia
Product Directory Allen-Bradley FactoryTalk
Services
Asset Optimization & Workforce Services
Asset Optimization Services Overview Equipment Repair Equipment Remanufacturing Repair and Inventory Agreements Integrated Service Agreements Remote Support & Monitoring Onsite & Field Services Safety Services Training Services
Cybersecurity & Network Infrastructure
Cybersecurity Industrial Network Infrastructure Pre-Engineered Network Solutions
Digital Thread
Overview
Production Automation
Overview Coordinated Drive System Solutions
Loading
LifecycleIQ Services
Solutions & Industries
Solutions
Advanced Motion & Robotics Asset Management Cybersecurity Data Operations & Analytics Digital Thread Digital Transformation Industrial Automation Control Industrial Components Networks & Infrastructure On-Machine Solutions
Packaged Solutions Process Solutions Production Automation Production Operations Management Safety Solutions  Scalable Control & Visualization Smart Manufacturing Sustainable Solutions Workforce Enablement
 
Solutions for
OEMs
Industries
Automotive & Tire Cement Chemical Entertainment Fiber & Textiles Food & Beverage Household & Personal Care Hydrogen Infrastructure Life Sciences
Marine Metals Mining Oil & Gas Power Generation Print & Publishing Pulp & Paper Semiconductor Warehouse & Fulfillment Water Wastewater
Loading
View Case Studies
Support
Documentation
Technical Documentation Center Product Drawings & Wiring Diagrams Product Certifications Release Notes Technical Specifications
Product Support
Downloads Selection & Configuration Management
Training
Webinars Workforce Development Training Instructor-led Courses Certificate Programs Job Aids Training Workstations Learning+ Training Subscriptions
Contact Us
TechConnect Support Customer Care Software Portal Help General Inquiries
TechConnect Support
TechConnect Support

Get the knowledge and assistance for solving your technical challenges.

Learn More about TechConnect
Compatibility and Downloads (PCDC) Knowledgebase Literature Library Engage Online Community
Sales & Partners
Find a Partner
Go to the Partner Finder
 
Our PartnerNetwork
PartnerNetwork Program Digital Partners Distributor Partners Licensed Developers
Original Equipment Manufacturer (OEM) Partners Strategic Alliance Partners System Integrator Partners Technology Partners
Order Online
Software Subscriptions E-learning Training Instructor-led Training Learning+ Training Subscriptions
What is the PartnerNetwork™?
What is the PartnerNetwork™?

Our Rockwell Automation PartnerNetwork™ program gives our customers access to the best people, products, services and solutions to meet manufacturing goals and bring The Connected Enterprise to life.

Explore Now
myRockwellAutomation
Careers
Investors
PartnerNetwork Portal
Contact Us
Resources
Popular Resources
Compatibility & Downloads (PCDC) Knowledgebase Literature Library Lifecycle Status Learning+ Training Portal
 
Product Management
Asset Management (RAAMP) Installed Base Evaluation (IBE) My Equipment Self-Service Product Registration Repairs Service Contracts & Tickets Software Activation Software Subscriptions Sustainability Dashboard
 
Product Configuration and Selection
Advisor Bill of Materials CrossWorks Integrated Architecture Builder Product Catalog ProposalWorks Proposal Builder ProposalWorks Standards Builder Safety Automation Builder
 

 

View All Tools →

Select country or region
  • Belgique | Belgium
  • Argentina
  • Australia
  • Brasil
  • Canada
  • Colombia
  • Czech Republic
  • Denmark
  • Deutschland
  • España
  • Finland
  • France
  • Hungary
  • India
  • Indonesia
  • Ireland
  • Israel
  • Italia
  • México
  • Netherlands
  • New Zealand
  • Norway
  • Poland
  • Portugal
  • Puerto Rico
  • Romania
  • Russia
  • Schweiz | Suisse
  • Singapore
  • South Africa
  • Sweden
  • Turkey
  • Ukraine
  • United Arab Emirates
  • United Kingdom
  • United States
  • Österreich
  • 中国
  • 台灣, 中國
  • 日本
  • 한국
Select language
  • English
  • Deutsch
  • Español
  • Français
  • Italiano
  • Português
  • 日本語
  • 简体中文
  • 繁體中文
  • 한국어
Sign In Create an Account
Why Create an Account?
Create bills of materials, submit repair quotes, register products and more!

Manage your e-communication subscription preferences.

Manage your user profile.
Welcome, {0}
Residing Location
My Account Sign Out
Your recent searches
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
All
Products
Documents
Downloads
Suggested search terms
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
Results for "{0}"
View all results
Product results for "{0}"
Product Image
Product Image
Product Image
View all product results
Document results for "{0}"
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
View all document results
Download results for "{0}"
DownloadDownload
Catalog Numbers:
DownloadDownload
Catalog Numbers:
DownloadDownload
Catalog Numbers:
View all download results
Case Study | Food and Beverage
Recent ActivityRecent Activity
6 minute read

Perth County Ingredients Saves on Maintenance

Leveraging Fiix, by Rockwell Automation, manager cuts reactive maintenance by 54% and saved over $40,000 a year

Share This:

LinkedInLinkedIn
XX
FacebookFacebook
PrintPrint
EmailEmail
A heap of yellow egg powder on round, wooden cutting board with a half-cracked egg to the right.

Tom Dufton has worn many hats over the span of his 20-year career. While he started out as a licensed red seal 309 electrician, he now works as a maintenance/project manager at Perth County Ingredients (PCI), where he is fully honed in on introducing automation.

Tom has been hard at work modernizing the PCI facility he’s worked at since 2017, where he’s implemented a building automation system (BAS) and a computerized maintenance management system (CMMS)

. Implementing two plant-wide systems over a three-year span is no small feat. But the results speak for themselves:

  • A 54% drop in reactive maintenance
  • A 47% reduction in after-hours call-ins
  • A $40,000 decrease in maintenance costs

Tom has continued to roll out automation at seven additional facilities and has introduced condition-monitoring tools to help him and his team save time, collect better data, and improve the health of equipment. Let’s take a look at his roadmap to success.


Fighting fires all day, every day Tom joined PCI’s dried egg processing facility as a contractor back in 2012, so he already had in-depth knowledge of the plant when he took on his current role in 2017.

“When I started [full time], there was a large need for us to upgrade our facility. We needed new boilers, new chillers, that sort of thing,” says Tom. What’s more, the maintenance team was wasting time and resources. 100% of the maintenance was reactive—meaning the team couldn’t move beyond trying to put out fires all day.

Tom knew his facility was in desperate need of a solution that could let them get ahead of maintenance and plan it, rather than reacting to it. His team also had little insight into after-hours emergency calls. The maintenance team would get alerted, and someone would have to respond, whether it was pressing a reset button or a repeat problem that could easily be solved.

Using Fiix to tackle reactive maintenance and save time The facility’s BAS system was already in place, but Tom knew more was needed to get things under control. He needed solid CMMS software and made the choice to use Fiix, by Rockwell Automation. It didn’t take much to get started.

“It was quite simple,” says Tom about putting Fiix in place at his facility.


The minute you start adding assets, you start making work orders, you start making scheduled maintenance, your team stops relying on you for that day-to-day and asking ‘What would you like me to do today, Tom?’ Now you have that in the maintenance software.


Not only did implementing Fiix allow Tom to focus on managing the maintenance team, but it also gave him the value-added time to project manage a $4M CapEx investment for the facility.

As it turned out, Fiix was exactly the puzzle piece Tom’s facility needed. He started by providing tablets with the Fiix app

 to the entire maintenance team. The app allowed the team to log and look up work by scanning a QR code on an asset. It also gave them the power to access standard operating procedures (SOPs), old work orders, and the BAS in seconds. All of this helped to shave hours off of the time it took to troubleshoot a problem, especially when it came to managing contractors.

“We put WiFi throughout the entire plant, which has allowed us to use tablets and cell phones to access Fiix,” says Tom.

And when you have all that scheduled maintenance in the system with pictures and asset tags and so on, you can set contractors up with that information and your team doesn’t need to be disrupted.

Automating maintenance across the whole company The VP of operations at PCI noticed the success at Tom’s facility and asked Tom to start rolling out Fiix out at more facilities. This led Tom to implement the CMMS at seven other L.H. Gray facilities across the country.

“The automation within our facility has basically allowed us to run multiple operations from one location,” says Tom about the benefits of this project.


"I get email alarms along with the production manager, so our fingers are always on the pulse of the facility. Without being there, you still know what's happening."


“Putting in these measures for automation has allowed us to bring down the number of people who need to be in one place at one time,” says Tom.

What’s more, the control that Fiix gives Tom has allowed him to roll out the remaining implementations remotely, with no plans of slowing down anytime soon.

“If you’re standing still, you’re falling behind,” says Tom. “We are constantly driving for more automation and growing.”

The search for maximum maintenance efficiency Tom’s strategy was working. Reactive maintenance was down 54% and after-hours call-ins were down 47%. But there was still plenty of room for improvement.

Preventive maintenance was still being scheduled based on old habits. A compressor would be checked every few weeks, even if it was operating perfectly. Oil changes relied on whether technicians thought the oil was good or bad. And inspections were still being done manually. The team was spending hours checking meter readings and logging data every week.

And while asset failure and fire fighting were down, Tom knew tasks like these were costing his team time and money they could be using somewhere else. So he set out to cut them from the schedule.

There was just one problem—Tom didn’t have the information he needed to pinpoint those jobs or the tools to automate them. So he teamed up with Fiix’s integration partner Majik Systems 

to find a solution.

Saving $40,000 a year with condition-based maintenance With the help of Fiix and Majik, Tom connected the facility’s PLCs to his CMMS. This gives him the power to collect real-time information about the condition of equipment. Now he can track vibration, temperature, or any other machine reading.

But this data would be next-to-useless without the link between Majik and Fiix. This connection allows asset data to flow into Tom’s CMMS without him lifting a finger. If a reading hits a certain threshold, a work order is created.

The best part is, the integration was done remotely. And it took only two weeks from start to finish (with less than a day’s work for Tom and his team).

“We now have alarms that are tripped and warnings to operators that if action is not taken or maintenance isn’t contacted that it could shut them down,” says Tom.


"The plant runs 24/7, but maintenance is only here Monday to Friday. So it’s very important that we’re capturing all this information … because when we see a change in the condition of an asset, we need to take action."


Fiix majik benefit illustration Rockwell Automation

The results have been immediate and significant. It’s been nine months since Tom put Majik in place and has already cut costs by $40,000 from decreasing breakdowns and shedding unnecessary jobs from his team’s to-do list. This is a 300% return on his original investment in the project.

We’ve seen old issues fall off. Things like motor pumps and bearings replacements. They’ve all decreased. And the value of connecting Fiix and Majik will only increase as Tom continues to find ways to optimize his maintenance schedule and help his company make smarter CapEx decisions.

“[With Fiix and Majik] you can collect all the work orders and repair costs for everything and you present that to your owners and you can say, we can continue down this path or we can get a new one,” says Tom.

And that’s a piece of ROI. By gathering the data, you’re able to give people real-world information and provide a snap-shot of the facility and tell them where it’s headed.

Calculate the ROI you could be getting with Fiix

.

Fiix Logo

Published May 23, 2022

Topics: Food & Beverage Industrial Maintenance & Support Fiix CMMS
Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe
Recommended for You
Loading
  1. Chevron LeftChevron Left United Kingdom Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Company
About Us Accessibility Careers Diversity, Ethics and Integrity Engage Online Community Investor Relations Modern Slavery Statement Sustainability Trust Center
 
News & Events
Newsroom Press Releases Automation Fair Upcoming Events
 
Trending Topics
Cybersecurity Digital Transformation Smart Manufacturing The Connected Enterprise®
 
Training
Webinars Workforce Development Training
 
PartnerNetwork
Find a Partner What is the PartnerNetwork?
 
Our Brands
Allen-Bradley FactoryTalk LifecycleIQ Services
Contact Us
TechConnect Support Customer Care General Inquiries How to Buy Report Ethical Concerns
Insights
ROKStudios Management Perspectives Results Achieved Case Studies Blogs Automation Today Podcasts
BlogRockwell Automation's Blog
BE | EN
Legal Notices
Privacy & Cookies Policy
Email Preferences
Cookie Settings
Accessibility Settings
© 2025 Rockwell Automation
United Kingdom
Please update your cookie preferences to continue.
This feature requires cookies to enhance your experience. Please update your preferences to allow for these cookies:
  • Social Media Cookies
  • Functional Cookies
  • Performance Cookies
  • Marketing Cookies
  • All Cookies
You can update your preferences at any time. For more information please see our Privacy Policy
CloseClose