Published: March 08, 2016  Updated: April 24, 2025

Big River Resources Enhances Ethanol Production with Strategic CMMS Application

In the demanding realm of ethanol production, the consistent operation of machinery directly impacts profitability. Any lapse in equipment functionality can swiftly translate into significant financial losses. This underscores the critical role of efficient maintenance practices. A powerful tool in achieving heightened efficiency and minimizing disruptions is the implementation of a Computerized Maintenance Management System (CMMS).

Big River Resources' Decade of CMMS Excellence with Mapcon

For nearly a decade, Big River Resources, a prominent US ethanol producer, has harnessed the capabilities of CMMS software at its Boyceville, Wisconsin, facility. Joe Boesl, the CMMS technician at the plant, emphasizes the indispensable nature of this technology, asserting that the facility would face considerable challenges without it. The CMMS solution comes from Mapcon Technologies, a recognized leader in the field, whose systems currently support operations in over 80 ethanol plants across the nation.

Proactive Maintenance: The Cornerstone of Operational Integrity

A primary function for Big River Resources’ utilization of its CMMS involves the meticulous execution of preventive maintenance tasks. These encompass routine inspections and procedures vital for the sustained health and functionality of their equipment. Boesl’s team routinely conducts thorough checks of machine indicators, ensuring all readings remain within designated safe parameters. This proactive approach mitigates the likelihood of unexpected failures and contributes to a safer operating environment.

Seamless Task Management and Planning

The Mapcon CMMS significantly simplifies the management of these crucial preventive tasks. Each time a user logs into the system, the welcome menu prominently displays the number of assigned work orders, providing immediate visibility into pending responsibilities. Furthermore, the system facilitates the generation of reports detailing upcoming work, empowering the facility to proactively plan its maintenance schedule and allocate resources effectively. This foresight minimizes disruptions and ensures timely attention to critical equipment.

Ensuring Regulatory Adherence and Audit Preparedness

Beyond its role in maintaining operational efficiency, preventive maintenance plays a vital part in adhering to regulations set forth by agencies such as OSHA and the Environmental Protection Agency (EPA). When a maintenance task completes within Mapcon, personnel can readily document if the action fulfills specific certification requirements. For instance, EPA mandates may necessitate regular checks of machine indicators in ethanol plants to verify that chemical levels, such as sulfur dioxide, remain within safe limits. During regulatory audits, Big River Resources can swiftly access comprehensive reports within Mapcon, outlining all completed equipment maintenance tasks undertaken to meet these stipulations. This readily available information proves invaluable, particularly for ethanol plants navigating stringent EPA guidelines, ensuring continuous compliance.

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Efficient Work Order Management for Timely Repairs

While consistent preventive maintenance significantly curtails the incidence of equipment failures, occasional repairs remain inevitable. When an issue arises, the CMMS provides an efficient mechanism for initiating the repair process through the submission of work requests. This can occur conveniently via a web browser, a mobile phone, or even through email, ensuring that maintenance needs are communicated promptly and effectively.

Expediting the Repair Workflow

At Big River Resources’ Wisconsin plant, for example, the discovery of a cracked or leaking fermentation tank prompts personnel to complete and submit a detailed work request. Leveraging the Mapcon mobile application allows for the inclusion of photographs directly within the work order, providing valuable visual context for the maintenance team. Upon submission, the appropriate personnel receive a notification and subsequently approve the request, which then generates a formal work order. Following this, the repair work undergoes meticulous planning, incorporating time estimates and necessary parts, before being dispatched to the assigned technician.

Centralized Asset Information for Swift Action

A key advantage of implementing a CMMS lies in its ability to provide maintenance technicians with rapid and straightforward access to crucial equipment and asset information. Instead of time-consuming searches, a technician can simply consult the CMMS to pinpoint the exact location of the equipment, along with the tools and replacement parts required for the repair. This precise knowledge of location and necessary resources significantly reduces the time needed to restore the machine to operational status.

Furthermore, beyond a single facility, Mapcon CMMS connects different operational sites, granting users visibility into parts availability across all locations. This interconnectedness has proven beneficial for Boesl, enabling him to identify and source parts from other Big River Resources facilities when urgently needed at his Wisconsin location. Once a required part locates at another site, a stockroom transfer request initiates its shipment, preventing potentially lengthy delays associated with ordering new parts and waiting for delivery.

Comprehensive Record Keeping and Analysis

Upon completion of the repair, the maintenance technician updates the work order and formally closes it within the CMMS. The capability to perform this task via a mobile device enhances data accuracy and reduces the time spent on manual paperwork. Technicians can input information in real-time using their portable devices, eliminating the need for later data entry at a desktop computer.

In situations demanding immediate attention where generating a formal work order beforehand proves impractical, an "after-the-fact work order" can be created. Once closed, this record moves into the system’s history, accessible later under the specific piece of equipment. This comprehensive work order history provides valuable insights for Big River Resources, enabling them to track the cumulative cost of repairs for each machine and assess its likelihood of future breakdowns.

The CMMS also facilitates the planning and tracking of man-hours associated with maintenance tasks. Within each work order, an estimated completion time can be recorded alongside the actual time taken. Generated reports then allow for a comparison between estimated and actual repair times, aiding the plant in analyzing repair costs and making informed decisions regarding the economic viability of future repairs versus equipment replacement.

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Beyond Repairs: Strategic Inventory and Purchase Management

While the efficient handling of repairs represents a critical function, CMMS software extends its utility to other vital operational areas, notably inventory and purchase management. Mapcon’s integrated inventory module empowers users to define minimum stock levels for each part. When the inventory of a particular item falls below this threshold, the system automatically generates a purchase request.

For instance, when Big River Resources’ supply of belts dwindles, the CMMS proactively initiates a request for replenishment, eliminating the need for manual intervention. This automated process helps prevent critical stockouts and ensures the availability of necessary components.

Simplified Procurement Processes

Furthermore, the system consolidates all outstanding purchase requests onto a single screen, providing the purchasing agent with a clear overview of required parts. This centralized view simplifies the approval and ordering process. This feature proves particularly advantageous as maintenance personnel may not always recognize the need to reorder parts until supplies are critically low. The failure of a crucial part without a readily available replacement can lead to significant and immediate financial losses due to prolonged machine downtime. By automating the purchase request process and providing a consolidated view of needs, the CMMS helps Big River Resources maintain optimal inventory levels and mitigate the risks associated with unexpected equipment failures.

Tailored Solutions for Specific Needs

In addition to its core functionalities, Mapcon Technologies offers its clientele a range of add-ons and customization options. This allows each CMMS implementation to be precisely tailored to the unique requirements and operational nuances of individual clients, ensuring maximum value and seamless integration with existing workflows.

The strategic adoption and consistent utilization of a CMMS like Mapcon at Big River Resources exemplify a commitment to operational excellence. This technology transcends mere record-keeping; it acts as a central nervous system for maintenance activities, fostering proactive planning, efficient execution, and informed decision-making, ultimately contributing to the sustained success of their ethanol production endeavors.

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