LLumin CMMS+ Case Studies

The Challenge

SunnyD needed to keep five plants running without unplanned downtime, spoilage, or safety risks. The maintenance team had to manage both modern and legacy equipment while meeting OSHA and FSMA requirements. They lacked clear visibility into parts and stockrooms across sites, which made it hard to plan PMs, avoid delays, and stay ahead of equipment failures.

The Solution

SunnyD implemented LLumin CMMS+ to centralize maintenance, inventory, and equipment data. The platform integrated with Microsoft Dynamics AX, automated procurement, and ensured critical parts were available before scheduled work. LLumin also supported time-based, usage-based, and IoT-driven PMs, giving the team real-time insight into equipment health and helping them shift to proactive maintenance.

Key Results

• Fewer delays and less downtime due to better scheduling and part availability
• Real-time equipment insight that supported earlier intervention
• Lower spoilage risk with more reliable production uptime
• Reduced inventory cost through company-wide visibility into shared stock
• Better OSHA and FSMA compliance with built-in safety procedures and mobile access to documents

The Challenge

Mataura Valley Milk (MVM) needed a CMMS that could support a high-performance dairy plant serving strict global markets. The team struggled to organize maintenance tasks, reduce downtime, and maintain food safety compliance while managing a wide range of equipment and processes. They required a system powerful enough to meet regulatory demands and flexible enough to match their own business processes.

The Solution

MVM adopted LLumin CMMS+ after seeing it in action at another dairy facility. The platform was fully configured to their maintenance processes, which made it easy for operators and technicians to use regardless of experience. LLumin provided real-time visibility into asset needs, integrated with their HMI system for fast work requests, and delivered automated workflows, notifications, and detailed activity logs to support both reliability and compliance.

Key Results

• Reduced equipment interruptions and downtime through proactive, condition-based maintenance
• Strengthened food safety compliance with detailed, auditor-ready reporting and clear activity logs
• Better scheduling and prioritization of maintenance work, along with improved inventory tracking and resource planning
• Faster repairs and simpler work request submission through LLumin’s HMI integration

The Challenge

Oceania Dairy needed a way to control safety risks, maintain strict food-quality standards, and keep a complex plant running without interruption. The team had to prevent combustible dust hazards, manage thousands of maintenance timelines, and deliver fast, accurate audit records. Paper-based processes made it difficult to track work, meet compliance expectations, and ensure no maintenance task was missed.

The Solution

The company adopted LLumin CMMS+ as a central system for scheduling work, tracking calibrations, organizing service requests, and maintaining complete maintenance histories. LLumin gave technicians and operators a user-friendly platform to submit work requests, automate tasks, and retrieve asset data instantly. The system also supported strict safety standards, simplified internal and external audits, and helped the team plan resources and prevent downtime through proactive scheduling.

Key Results

• Stronger protection against dust-explosion risks through structured maintenance and clear safety controls
• Faster, more accurate audits with instant access to maintenance records, calibration certificates, and activity logs
• Reduced downtime through proactive maintenance scheduling and better visibility into workforce capacity
• Up to 35 percent faster completion of maintenance tasks due to optimized workflows and clear task organization
• More consistent plant and product safety across a large workforce using a single, easy-to-use system

The Challenge

TenCate needed to establish lean, efficient maintenance processes across a 24/7 operation with more than 500 employees. Their existing system could not properly track work orders, retain maintenance history, or provide visibility into bottlenecks. The team also needed a CMMS that technicians would actually use and one that could integrate with control systems, MES, and ERP platforms to support growing production demands.

The Solution

TenCate selected LLumin CMMS+ for its balance of functionality, usability, and integration capabilities. LLumin connected directly to industrial control systems like Aveva and integrated with enterprise systems to centralize maintenance, purchasing, and inventory workflows. The platform enabled sensor-driven maintenance triggers, mobile work execution, and intuitive dashboards that operators and technicians could adopt quickly without extensive training.

Key Results

• Prevented catastrophic equipment failures through sensor-based condition monitoring and automated work orders
• Improved efficiency of maintenance work performed during scheduled shutdowns
• Streamlined purchasing and materials management by integrating CMMS and ERP workflows
• Increased lean maintenance visibility through HMI dashboards and operator-initiated work requests
• Improved wrench-time tracking and visibility into total equipment parts costs
• Faster inspections and maintenance execution using mobile barcode scanning and real-time updates

The Challenge

Miller Milling struggled with disconnected systems for work orders and purchasing across five mills and corporate headquarters. Outdated software and manual, paper-based processes made it difficult to track inventory accurately, manage approvals, and respond quickly when equipment failed. These gaps led to production delays, unnecessary purchases, and time-consuming invoicing workflows.

The Solution

Miller Milling implemented LLumin CMMS+ to consolidate work orders, purchasing, and inventory into a single digital platform. LLumin replaced paper invoices with one-click approvals, streamlined work order management, and gave teams real-time visibility into parts and assets across all locations. The system was configured to match Miller Milling’s processes and was easy for both maintenance and administrative teams to adopt.

Key Results

• Reduced invoicing time by up to 97 percent through fully digital approvals and payments
• Faster repairs and better maintenance planning with centralized work order tracking
• Improved inventory accuracy and cost control across five mills through shared visibility
• Fewer production delays caused by missing or mismanaged parts
• Improved productivity and morale by eliminating after-hours administrative work

The Challenge

PhilCorr had outgrown a rigid, legacy CMMS that limited data access and relied heavily on institutional knowledge. Unplanned downtime carried a high financial impact of $17,000 to $20,000 per hour, and manual procurement and AP workflows introduced delays and errors. The team also needed better coordination between maintenance, production, and accounting, along with a clean integration to their Amtech ERP.

The Solution

PhilCorr implemented LLumin CMMS+ to modernize maintenance, compliance, and procurement in one system. LLumin provided a flexible, asset-driven hierarchy, simple PM scheduling, and automated compliance and training task management. The platform integrated seamlessly with Amtech, reduced manual data entry, and gave teams real-time visibility into work history, inventory, and purchasing. LLumin worked closely with PhilCorr during implementation to align assets with general ledger accounts and streamline reporting.

Key Results

• Saves up to $20,000 per hour by reducing unplanned downtime through better PM planning
• Improved coordination between production and maintenance, minimizing disruptions
• Stronger compliance control by replacing memory-based processes with automated tracking
• Achieved approximately 99 percent AP accuracy by reducing manual invoice entry
• Greater visibility into inventory, procurement, and completed work across departments

The Challenge

Granite Falls Energy (GFE) relied on an outdated CMMS that required heavy manual input and could not be configured to match business processes. Maintenance teams managed hundreds of PMs each month using paper, spreadsheets, and disconnected systems. Asset tracking, reporting, and trend analysis were difficult, which limited visibility into equipment health and increased the risk of larger failures.

The Solution

Granite Falls Energy implemented LLumin CMMS+ to centralize work orders, purchasing, inventory, safety documentation, and reporting in one configurable platform. LLumin was tailored to GFE’s processes, allowing the team to build custom modules, templates, tags, and asset hierarchies. The system automated PM tracking, enabled electronic purchasing, improved reporting with visual trends, and made safety and compliance documentation instantly accessible to technicians.

Key Results

• Eliminated paper-based maintenance and manual asset tracking
• Improved visibility into nearly 5,600 assets with searchable records and trend analysis
• Faster identification of potential failures through historical data and visual reporting
• Streamlined purchasing and inventory management with automated reorder triggers
• Stronger safety, compliance, and MOC processes with centralized documentation
• Better communication and data sharing across departments

The Challenge

Red Cedar Gathering needed to improve uptime across a large, distributed natural gas operation with thousands of live data points. Diagnosis and repair cycles were slow and labor-intensive, and data exchange between operations and maintenance was fragmented. The team needed better visibility into equipment condition to reduce downtime and shorten MTTR.

The Solution

Red Cedar implemented LLumin CMMS+ with deep integration to IIoT sensors, control systems, and the data historian. The platform automated condition-based alerts, triggered proactive work orders, and centralized asset data for real-time decision-making. LLumin enabled predictive and preventive maintenance by monitoring temperatures, pressures, and other critical variables, while providing role-based dashboards for faster response.

Key Results

• Increased operations uptime to above 99 percent with full annual throughput
• Reduced labor hours and significantly shortened MTTR through automated alerts and workflows
• Faster diagnosis and response using real-time and historical condition data
• Predictive and proactive maintenance processes fully in place
• Improved equipment life and capital planning through continuous condition monitoring

The Challenge

The City of Brandon relied on manual, reactive maintenance processes to manage more than 3,500 assets across water, wastewater, utilities, and public works. Work requests arrived by email and were tracked in spreadsheets, which led to missed requests, slow response times, and a growing backlog. With strict provincial regulations and a fast-growing community, the city needed a scalable CMMS to support proactive maintenance and reliable service delivery.

The Solution

Brandon implemented LLumin CMMS+ to digitize maintenance operations and shift from reactive to proactive asset management. LLumin centralized work orders, recurring maintenance schedules, documentation, and reporting in a single system accessible in the office and in the field. Automated recurring work orders ensured critical assets were serviced on time, while mobile access and integrations supported daily planning, compliance, and future growth.

Key Results

• Achieved more than 10 years of proactive maintenance across critical municipal assets
• Significantly reduced breakdowns by automating recurring maintenance schedules
• Improved visibility into asset history, work orders, and maintenance trends
• Faster prioritization and execution of work through digital workflows and daily planning
• Scalable asset and inventory management to support city growth beyond 3,500 assets

The Challenge

The City of Savage relied on manual, paper-based maintenance processes as its population and utility infrastructure grew. The utility services department needed to manage more than 2,100 assets and over 10,500 water accounts, but lacked a modern system to track work, control costs, and plan maintenance proactively. Increasing unplanned service calls and limited visibility made it difficult to stay efficient and accountable.

The Solution

Savage implemented LLumin CMMS+ to replace paper workflows with a modern, predictive maintenance platform. LLumin centralized work orders, asset data, and meter tracking while providing automated alerts and reporting. The system uniquely identified and tracked every water meter, integrated maintenance and billing processes, and gave the department tools to plan work ahead of time rather than react to breakdowns.

Key Results

• Optimized maintenance planning with predictive alerts and proactive scheduling
• Centralized tracking of more than 2,100 assets and 10,500 water accounts
• Reduced unplanned maintenance and service disruptions
• Improved cost control and transparency through detailed reporting
• Stronger accountability to taxpayers with a clear audit trail of maintenance spending

The Challenge

Canisius College relied on paper-based processes to manage facilities maintenance, which made it difficult to track assets, work orders, and compliance records. The facilities team lacked real-time visibility into task status and crew activity, creating delays, manual errors, and limited accountability across campus operations.

The Solution

Canisius College implemented LLumin CMMS+ to digitize asset management and centralize all facilities work in a cloud-based platform. LLumin replaced paper workflows with real-time work order tracking, flexible customization, and intuitive reporting. The system enabled proactive scheduling, simplified daily operations, and gave the facilities team instant access to accurate data across campus.

Key Results

• Transitioned from paper-based maintenance to a fully digital, proactive process
• Real-time visibility into work orders, tasks, and asset status
• Improved accountability with detailed audit trails and compliance-ready reporting
• Streamlined maintenance for more than 659 rooms across campus
• Reduced administrative effort and human error through live updates and reporting

The Challenge

CAT’s Mapleton facility relied on an outdated, mainframe-based maintenance system that was difficult to use and no longer supported by IT. The system limited information sharing, required heavy manual entry, and made it hard for technicians to access asset data, PM schedules, and safety records. With a large, unionized workforce and no shift overlap, the plant needed a modern CMMS that could improve responsiveness, usability, and scalability.

The Solution

CAT implemented LLumin CMMS+ as a cloud-based, user-friendly maintenance platform. LLumin centralized asset data, work orders, preventive maintenance scheduling, and safety inspections in one system. Role-based dashboards ensured technicians and supervisors saw only what they needed, while automated workflows and mobile capabilities streamlined maintenance execution and knowledge sharing across shifts.

Key Results

• Automated preventive maintenance scheduling, eliminating manual PM setup
• Faster work order creation, assignment, and completion across the plant
• Improved productivity by centralizing asset history, instructions, and documentation
• Stronger OSHA compliance through electronic safety tracking and inspections
• Better shift-to-shift continuity with all maintenance information available in one system
• Improved service levels to the plant without increasing maintenance headcount