I. Overview of the Kick-Off Event

The kick-off event for Thang Long Tobacco implementing CMMS EcoMaint took place on May 15, at the company’s headquarters in Hanoi, Vietnam. It brought together key stakeholders from Thang Long Tobacco and Vietsoft’s expert team to align expectations and establish a clear roadmap for implementation. The event featured:

• Project Objectives Presentation: Vietsoft outlined how CMMS EcoMaint will streamline maintenance processes, reduce costs, and enhance equipment reliability.
• Requirement Gathering: Thang Long Tobacco shared specific needs, such as managing complex tobacco processing machinery and integrating with existing systems.
• Timeline and Responsibilities: A detailed project schedule was established, with milestones and roles assigned to ensure smooth execution.
• Commitment to Support: Vietsoft pledged comprehensive training and ongoing technical assistance to facilitate a seamless transition.

The event concluded with a shared commitment to leveraging CMMS EcoMaint to transform Thang Long Tobacco’s maintenance operations, setting the stage for operational excellence.

II. About Thang Long Tobacco Company Limited

1. A Legacy of Excellence in Vietnam’s Tobacco Industry

Established on January 6, 1957, Thang Long Tobacco Company Limited, originally known as Thang Long Tobacco Factory, is a trailblazer in Vietnam’s tobacco industry. In 2005, it became a state-owned limited liability company under Decision No. 318/2005/QĐ-TTG. Over its 68-year history, Thang Long Tobacco has cultivated a legacy of innovation and quality, significantly contributing to the growth of Vietnam’s tobacco sector.

2. Company Details:

• Full Name: Thang Long Tobacco Company Limited
• Abbreviation: Vinataba Thang Long
• Headquarters: 235 Nguyen Trai Street, Thanh Xuan District, Hanoi, Vietnam
• Contact: +84 243 858 4441 / +84 243 858 4342
• Email: contact@thanglongtabac.vn

3. Core Business and Achievements

Thang Long Tobacco specializes in:

• Manufacturing and trading cigarettes.
• Producing, processing, and repairing specialized tobacco equipment.
• Importing and exporting tobacco-related products.

With an annual production capacity exceeding 1 billion cigarette packs, the company leads Vietnam’s tobacco market and plays a vital role in global exports. Its products are distributed across the Middle East, Africa, Southeast Asia, Singapore, South Korea, Europe, and the United States. Thang Long Tobacco’s commitment to quality is evident in its rigorous technological processes, ensuring 100% product compliance with domestic and international standards.

In 2024, despite global economic challenges, Thang Long Tobacco achieved outstanding results:

• Revenue: 8,677.9 billion VND (approximately $350 million USD), up 14.3% from 2023, exceeding the plan by 10.79%.
• Tax Contribution: 5,575.8 billion VND, a 10.2% increase, surpassing the target by 6.14%.
• Pre-Tax Profit: 242.25 billion VND, up 10.78%, beating the plan by 5.24%.
• Return on Equity: 9.22%, exceeding the target by 35.59%.

These achievements reflect Thang Long Tobacco’s resilience and strategic focus on efficiency and market expansion.

4. Production Processes

Thang Long Tobacco’s production involves two critical processes:

a. Tobacco Processing:

o    Raw tobacco leaves, packed in 200kg bales, are processed into cigarette-ready threads.

o    Advanced equipment from Hauni (Germany) and Dickinson Legg (UK), including KT2 cutting machines, air-drying systems, and Tobacco Scan II for impurity detection, ensures precision.

o    Operating 24/7, the factory produces over 4 tons of tobacco threads per hour (17,000 tons annually), accounting for one-third of Vietnam’s tobacco production.

b. Packaging:

o    High-speed machines automate cigarette production, filter assembly, and packaging into branded packs, protective wraps, and cartons.

o    Automated quality checks ensure each cigarette meets technical specifications, minimizing defects.

5. Vision for the Future

Thang Long Tobacco aims to maintain its leadership in Vietnam’s tobacco industry while expanding global partnerships. By investing in modern technology and digital transformation, the company is poised to enhance competitiveness and meet evolving consumer demands.

III. Why Thang Long Tobacco Implements CMMS EcoMaint

1. Challenges in Traditional Maintenance Management

Thang Long Tobacco operates sophisticated machinery, such as Hauni’s 6-ton-per-hour tobacco processing lines, which require meticulous maintenance to ensure continuous operation. Traditional maintenance methods, relying on Excel spreadsheets, paper-based work orders, or informal communication tools like Zalo, pose challenges:

• Inefficient Tracking: Difficulty in monitoring equipment history and maintenance schedules.
• Unplanned Downtime: Unexpected breakdowns disrupt production, impacting revenue.
• Inventory Mismanagement: Overstocking or shortages of spare parts increase costs.
• Lack of Data Insights: Limited visibility into maintenance costs and equipment performance hinders decision-making.

To address these issues, Thang Long Tobacco implementing CMMS EcoMaint is a strategic move to modernize maintenance operations and align with Industry 4.0 trends.

2. Strategic Objectives

By adopting CMMS EcoMaint, Thang Long Tobacco aims to:

• Reduce Downtime: Implement preventive maintenance to minimize unexpected equipment failures.
• Optimize Costs: Streamline spare parts inventory and control maintenance expenses.
• Enhance Equipment Longevity: Extend the lifespan of critical machinery.
• Improve Decision-Making: Leverage data-driven insights for strategic planning.
• Support Digital Transformation: Integrate maintenance management into the company’s broader digitalization efforts.

IV. Key Features of CMMS EcoMaint for Thang Long Tobacco

CMMS EcoMaint, developed by Vietsoft, is a comprehensive, cloud-based solution tailored for manufacturing enterprises like Thang Long Tobacco. Below are the key features that will empower Thang Long Tobacco’s maintenance operations:

1. Comprehensive Asset Management

• Asset Information: Stores detailed records of each piece of equipment, including model, specifications, and maintenance history.
• Asset Hierarchy: Organizes equipment in a tree structure for complex systems, such as Hauni’s tobacco processing lines.
• QR Code Integration: Enables quick access to asset details via mobile devices by scanning QR codes.

2. Preventive Maintenance Planning

• Scheduled Maintenance: Automates maintenance schedules based on time, usage hours, or performance metrics (e.g., tons of tobacco processed).
• Work Order Automation: Generates work orders for routine inspections, calibrations, or repairs.
• Maintenance Windows: Identifies optimal times for maintenance to minimize production disruptions.

3. Real-Time Equipment Monitoring

• Condition-Based Monitoring: Integrates with IoT sensors to track equipment parameters like temperature, vibration, or power consumption.
• Instant Alerts: Sends notifications for anomalies, enabling proactive interventions.
• Downtime Tracking: Logs downtime events to analyze causes and prevent recurrence.

4. Spare Parts Inventory Management

• Inventory Tracking: Monitors stock levels of spare parts, such as filters or blades for KT2 machines.
• Purchase Requisitions: Automates requests for restocking when inventory falls below minimum levels.
• Cost Optimization: Reduces overstocking and shortages, lowering inventory costs by 10-20%.

5. Workforce Management

• Employee Profiles: Maintains records of maintenance staff skills and certifications.
• Task Assignment: Assigns tasks to technicians based on expertise and availability.
• Labor Tracking: Records time spent on maintenance tasks for performance analysis.

6. Advanced Reporting and Analytics

• Equipment Performance Reports: Tracks Overall Equipment Effectiveness (OEE) to assess machine availability and efficiency.
• Cost Analysis: Provides detailed breakdowns of maintenance expenses, helping identify cost-saving opportunities.
• Customizable Dashboards: Displays real-time KPIs, such as downtime hours or maintenance completion rates, in visual formats like charts.

7. Mobile Accessibility

• Mobile App: Allows technicians to access work orders, report issues, and update statuses on the go.
• Photo/Video Uploads: Enables staff to document equipment conditions for better diagnostics.
• Multilingual Support: Offers English and Vietnamese interfaces, ideal for Thang Long Tobacco’s FDI partners.

8. System Integration

• ERP Compatibility: Integrates with existing ERP systems for seamless data sharing.
• IoT and AI Support: Connects with Vietsoft’s IoT solutions for predictive maintenance.
• Third-Party Tools: Links with accounting or warehouse software to streamline operations.

V. Benefits of Thang Long Tobacco Implementing CMMS EcoMaint

The implementation of CMMS EcoMaint is expected to deliver transformative benefits to Thang Long Tobacco, aligning with its goals of efficiency, cost savings, and digitalization. Based on Vietsoft’s case studies and industry benchmarks, the following outcomes are anticipated:

1. Reduced Downtime

• Preventive maintenance schedules and real-time monitoring will minimize unplanned outages, ensuring continuous production.

2. Cost Savings

• Optimized spare parts inventory and streamlined maintenance processes will lower operational costs.

3. Extended Equipment Lifespan

• Regular maintenance and condition-based interventions will prolong the life of critical assets, such as Hauni’s 6-ton-per-hour processing lines.

4. Improved Productivity

• Automated work orders and mobile access will enable technicians to complete tasks faster, boosting overall productivity.

5. Enhanced Inventory Management

• Real-time inventory tracking will reduce spare parts stock by 10-20%, freeing up capital and storage space.

6. Data-Driven Decision-Making

• Comprehensive reports and dashboards will provide insights into equipment performance, maintenance costs, and workforce efficiency, enabling strategic investments.

7. Seamless Digital Transformation

• CMMS EcoMaint will integrate with Thang Long Tobacco’s existing IT infrastructure, supporting its broader digitalization goals.
• Vietsoft’s solutions have enabled over 300 Vietnamese enterprises to advance toward smart factory models.

VI. Implementation Roadmap for Thang Long Tobacco

The deployment of CMMS EcoMaint at Thang Long Tobacco follows a structured, 8 step process to ensure success:

Step 1: Identify Core Challenges (May 2025)

• Assess current maintenance pain points, such as unplanned downtime and inventory inefficiencies.
• Define objectives, including reducing downtime by 20% and maintenance costs by 10%.

Step 2: Define Functional Requirements (June 2025)

• Categorize features as “mandatory” (e.g., preventive maintenance) or “optional” (e.g., IoT integration).
• Prioritize needs based on Thang Long Tobacco’s production demands.

Step 3: Software Evaluation (June 2025)

• Vietsoft demonstrates CMMS EcoMaint’s capabilities through demos and case studies.
• Thang Long Tobacco validates alignment with operational requirements.

Step 4: Engage with Vietsoft (July 2025)

• Finalize contract terms, including customization, pricing, and support.
• Review Vietsoft’s track record, with no failed projects in over a decade.

Step 5: Prepare Workforce (July 2025)

• Appoint a project leader (e.g., maintenance manager) and a team of experienced technicians.
• Ensure staff are trained in basic software usage.

Step 6: Data Preparation (August 2025)

• Collect data on equipment, spare parts, and maintenance history.
• Standardize coding for assets (e.g., “TDBGT001” for gear components) to avoid duplication.

Step 7: System Deployment (September-October 2025)

• Import data into CMMS EcoMaint via Excel files.
• Configure user permissions and test workflows.
• Train users based on roles (e.g., technicians, managers, admins).

• Define thresholds for alerts (e.g., excessive vibration in drying systems).

Step 8: Evaluate and Optimize (November 2025)

• Analyze CMMS data to assess downtime reduction and cost savings.
• Adjust maintenance strategies based on insights, such as increasing inspection frequency for high-risk assets.

 

VII. Why Vietsoft’s CMMS EcoMaint is Ideal for Thang Long Tobacco

Vietsoft, with over 20 years of experience in CMMS solutions, is a trusted partner for Thang Long Tobacco. Key reasons for choosing CMMS EcoMaint include:

• Proven Success: Implemented in over 300 Vietnamese enterprises, including FDI and local firms, with a 100% success rate.
• Tailored for Vietnam: Designed to support both automated and semi-automated equipment, addressing Thang Long Tobacco’s diverse machinery.
• Cost-Effective: Competitive pricing ensures a rapid return on investment, typically within six months.
• Expert Support: Vietsoft’s consultants, trained with leading institutions like Hanoi University of Science and Technology, provide hands-on guidance.
• Cloud-Based Flexibility: Accessible via web and mobile, supporting Thang Long Tobacco’s multi-shift operations.

 

VIII. Real-World Impact: Vietsoft’s Success Stories

Vietsoft’s CMMS EcoMaint has delivered measurable results across industries, offering a glimpse of what Thang Long Tobacco can expect:

• Port Operator (2015-2023): Reduced equipment failure rates from 2.03 to 0.1 incidents per machine annually, cutting emergency repairs by 92%.
• Lam Viet Corporation (2024): Decreased downtime by 42.2% (1,790 hours) over four months, saving tens of thousands of USD.
• Instant Noodle Manufacturer: Reduced unexpected failures by 36% in two months.
• Vietnam-Germany University: Halved failure rates in one month.

These outcomes highlight CMMS EcoMaint’s ability to drive efficiency and reliability, making it a perfect fit for Thang Long Tobacco’s high-stakes production environment.

 

IX. Conclusion: A Bright Future for Thang Long Tobacco with CMMS EcoMaint

Thang Long Tobacco implementing CMMS EcoMaint is more than a technology upgrade—it’s a strategic investment in operational excellence and digital transformation. By streamlining maintenance, reducing costs, and enhancing equipment reliability, CMMS EcoMaint will empower Thang Long Tobacco to maintain its leadership in Vietnam’s tobacco industry while expanding its global footprint. With Vietsoft’s expertise and a clear implementation roadmap, this project is poised to deliver transformative results.

Are you a manufacturing enterprise looking to optimize asset maintenance? Explore the CMMS EcoMaint solution here.

Contact us for consultation via hotline: 0986778578 or email: sales@vietsoft.com.vn.