When the world's leading gluten-free foods manufacturer needed to standardize maintenance operations across 12 production sites in 9 countries, it turned to cutting-edge enterprise asset management (EAM) technology. Dr. Schär successfully implemented Ultimo's cloud-based EAM solution to transform its maintenance workflows, reduce downtime, and drive operational excellence across its global manufacturing network - all while maintaining the highest quality standards that have made it a trusted international brand.

Dr. Schär stands as a remarkable success story in specialized nutrition. From its humble beginnings as a South Tyrolean family business, the company has evolved into the world's undisputed market leader for gluten-free products and foods for people with special dietary needs. Today, with over 1,800 employees across 12 countries and 18 sites worldwide, Dr. Schär has built its reputation on innovation through research, largely self-developed production techniques, and uncompromising quality standards.

But success at this scale brings unique challenges. Dr. Schär relies on highly complex, often proprietary production techniques. Each of its production facilities operates an average of 400 machines across multiple production lines, and all must adhere to uniform standards that reflect the company's commitment to excellence.

The maintenance management system that had served Dr. Schär in its earlier years no longer aligned with its global ambitions. The maintenance extension of the enterprise resource planning (ERP) system it was using had limited functionality and a lack of detail that meant effective organization and planning were increasingly difficult. Without mobile access capabilities, field operations were constrained, and the growing complexity of the company’s international operations demanded a more sophisticated approach.

To maintain its position as industry leader, Dr. Schär acknowledged that it needed a maintenance management solution that could match its own best-in-class standards.

Enterprise Asset Management Excellence

Having conducted a thorough evaluation of multiple providers, Dr. Schär chose the enterprise asset management solution from Ultimo, an IFS company.

"We chose Ultimo as our maintenance management solution because its cloud-based EAM solution offers the most comprehensive capabilities and aligns perfectly with our own best-in-class standards," explains Martin Lorefice, Corporate Technical Project Manager at Dr. Schär.

The initial implementation at Dr. Schär's headquarters in Burgstall, South Tyrol, Germany, demonstrated the solution's potential. Completed successfully in just six months, this pilot implementation provided the foundation for the broader international rollout.

However, the project's complexity extended far beyond technical considerations. One of the key challenges was adapting the EAM software to fit Dr. Schär's well-established processes rather than forcing the company to change processes to accommodate the software. This approach preserved the operational excellence that had made Dr. Schär successful while enhancing it with modern digital capabilities.

Simultaneously, the project aimed to harmonize maintenance workflows across all production sites - a significant undertaking given the varying levels of maturity in maintenance management across different locations. With multiple stakeholders and departments involved, the rollout required careful orchestration and an implementation plan that assured employee acceptance.

A multi-phase implementation plan was developed to ensure employee acceptance and smooth transitions. This methodical approach has proven successful, with the international rollout continuing to progress according to plan.

The implementation strategy is as ambitious as it is necessary. Ultimo will be rolled out across 12 production sites in 9 countries for managing maintenance tasks. The project represents a fundamental transformation of how Dr. Schär approaches maintenance management on a global scale.

Data-Driven Optimization

Martin Lorefice, who leads the project at Dr. Schär, is highly satisfied with both the progress and initial results achieved. He explains, "Ultimo is a key part of our digitalization strategy. The more data we collect through the EAM solution, the more visible the benefits and improvements become."

“With the introduction of Ultimo, we have successfully transitioned from reactive to preventive maintenance,” says Lorefice. “This shift has already reduced equipment downtime by approximately 30 percent. We have also seen a noticeable improvement in our mean time to repair. Going forward, we’ll be tracking these metrics even more precisely - giving us a solid data foundation for further optimizing our maintenance operations.”

This data-centric approach is central to Dr. Schär's vision for the future. The information collected through Ultimo is positioned to play a crucial role in optimizing processes, reducing downtime, and simplifying compliance documentation - all critical factors in food production where quality and efficiency are paramount.

The company's main objectives with Ultimo implementation are ambitious yet achievable. By reducing maintenance efforts, Dr. Schär expects to lower production costs while increasing overall efficiency. The streamlined maintenance operations are anticipated to deliver multiple benefits: shorter training times for technicians, reduced spare parts consumption, lower inventory costs, and improved cost control.

Setting New Standards for Global Manufacturing

Dr. Schär's implementation of Ultimo represents more than a technology upgrade. It's a strategic transformation that positions the company for continued growth and excellence in the competitive global food industry. By choosing a solution that adapts to their processes rather than forcing process changes, Dr. Schär has maintained its operational DNA while gaining the digital capabilities necessary for future success.

As the international rollout continues, Dr. Schär is not just improving its own operations; the company is setting new standards for how global food manufacturers can leverage EAM technology to achieve operational excellence at scale. The project demonstrates that with the right approach and technology partner, even the most complex international manufacturing operations can be transformed while preserving the quality and standards that define market leadership.