In the fast-paced world of manufacturing, ensuring operational efficiency and maintaining high-quality standards are critical for success. ASIA DRAGON CORDAGE, a leading Vietnamese manufacturer of ropes and synthetic fibers, has taken a significant step toward operational excellence by implementing the EcoMaint CMMS (Computerized Maintenance Management System) solution from Vietsoft. This article explores the journey of ASIA DRAGON CORDAGE implementing the CMMS software, the company’s background, the features and benefits of EcoMaint, and how this solution drives efficiency and reliability in their operations.
I. Introduction to ASIA DRAGON CORDAGE
Founded on July 11, 2006, ASIA DRAGON CORDAGE (officially known as Asia Dragon Investment Joint Stock Company) has established itself as a pioneer in Vietnam’s rope and synthetic fiber industry. As the first Vietnamese company to produce synthetic fibers for agriculture and industrial applications, ASIA DRAGON CORDAGE has earned a reputation for delivering high-quality products that meet international standards. With an annual production capacity exceeding 2,400 tons, the company exports ropes, twines, and synthetic fibers to demanding markets such as North America, Europe, Australia, and South America.
The company’s product portfolio includes agricultural fibers for greenhouse support, banana tying, and crop trellising, as well as ropes for maritime applications, safety equipment, and industrial uses. These products are manufactured using state-of-the-art machinery from globally renowned brands like Starlinger, Roblon, Sima, Diing Kuen, and Dea Young. Certified with ISO 9001:2015 and other international standards, ASIA DRAGON CORDAGE’s products are trusted by partners in advanced agricultural and industrial markets worldwide.
Under the leadership of Ms. Nguyễn Việt Hòa, the company’s General Director, ASIA DRAGON CORDAGE has grown steadily over the past 24 years, positioning itself among the top five suppliers in the U.S. market and top three in Australia. With a workforce of 101–200 employees and a registered capital of VND 39.8 billion, the company remains committed to innovation, quality, and sustainability.
II. The Need for a CMMS Solution at ASIA DRAGON CORDAGE
As a leading manufacturer, ASIA DRAGON CORDAGE relies heavily on its advanced machinery to maintain consistent product quality and meet the stringent demands of its international clients. However, managing a large fleet of equipment across its production facility in Tân Tạo Industrial Park, Ho Chi Minh City, presented challenges. Unplanned downtime, inconsistent maintenance schedules, and the risk of equipment failure could jeopardize production efficiency and product quality.
Recognizing the importance of digital transformation, ASIA DRAGON CORDAGE embarked on a journey to optimize its maintenance processes. After evaluating multiple solutions and consulting with industry experts, the company partnered with Vietsoft, a trusted provider of software solutions in Vietnam, to implement the EcoMaint CMMS. This decision, formalized on April 27, 2018, marked a pivotal moment in the company’s digitalization strategy.
III. Why ASIA DRAGON CORDAGE Chose EcoMaint CMMS
The decision to implement EcoMaint was driven by the need for a robust, user-friendly system that could streamline maintenance operations while aligning with the company’s goals of quality assurance and operational efficiency. EcoMaint, developed by Vietsoft in collaboration with leading technical universities like Ho Chi Minh City University of Technology and the University of Industrial Technology, is a proven CMMS solution tailored to the needs of both Vietnamese and FDI enterprises.
IV. Key Features of EcoMaint CMMS
EcoMaint offers a comprehensive set of tools designed to optimize maintenance management. Below are the key features that make EcoMaint an ideal choice for ASIA DRAGON CORDAGE:
1. Asset Management: EcoMaint provides a centralized database to track all equipment, including details such as model, serial number, maintenance history, and warranty information. This ensures ASIA DRAGON CORDAGE has full visibility into its asset inventory.
2. Preventive Maintenance Scheduling: The system allows the company to schedule regular maintenance tasks, reducing the risk of unexpected breakdowns. For example, routine inspections of Starlinger or Roblon machines can be automated to ensure optimal performance.
3. Work Order Management: EcoMaint streamlines the creation, assignment, and tracking of work orders. Maintenance teams at ASIA DRAGON CORDAGE can prioritize tasks, assign technicians, and monitor progress in real time.
4. Inventory Management for Spare Parts: The software tracks spare parts inventory, ensuring that critical components for machinery are always available. This minimizes downtime caused by delays in sourcing parts.
5. Real-Time Reporting and Analytics: EcoMaint generates detailed reports on equipment performance, maintenance costs, and downtime. These insights enable data-driven decision-making, helping ASIA DRAGON CORDAGE optimize resource allocation.
6. Mobile Accessibility: With mobile access, technicians can update maintenance records, access work orders, and report issues on the go, improving response times and operational efficiency.
7. Compliance and Quality Control: EcoMaint supports compliance with international standards like ISO 9001:2015 by maintaining detailed records of maintenance activities, ensuring traceability and accountability.
V. Benefits of EcoMaint for ASIA DRAGON CORDAGE
By implementing the EcoMaint CMMS, ASIA DRAGON CORDAGE has unlocked numerous benefits that enhance its operational capabilities:
- Reduced Downtime: Proactive maintenance schedules minimize unexpected equipment failures, ensuring continuous production and timely delivery to clients in Europe, the U.S., and Australia.
- Improved Product Quality: Consistent equipment performance reduces the risk of defects, ensuring that ropes and fibers meet the high standards expected by international markets.
- Cost Savings: Optimized maintenance and inventory management lower operational costs by reducing emergency repairs and overstocking of spare parts.
- Enhanced Decision-Making: Real-time data and analytics provide insights into equipment health, enabling the management team to make informed decisions about maintenance budgets and investments.
- Scalability: As ASIA DRAGON CORDAGE expands its product lines, such as the introduction of polyester straps for telecommunications, EcoMaint can scale to accommodate new assets and processes.
VI. The Implementation Journey of EcoMaint at ASIA DRAGON CORDAGE
The implementation of EcoMaint at ASIA DRAGON CORDAGE was a meticulously planned process, executed in collaboration with Vietsoft’s experienced implementation team. The project followed a structured approach to ensure a seamless transition and maximize the system’s effectiveness. Below is a detailed overview of the implementation stages:
1. Needs Assessment
Vietsoft began by conducting an in-depth audit of ASIA DRAGON CORDAGE’s equipment and maintenance processes. This involved mapping over 150 assets, including high-tech production machines like Starlinger extruders and Roblon twisting machines. The assessment identified key pain points, such as inconsistent maintenance schedules and manual record-keeping, and aligned the solution with the company’s operational goals.
2. System Customization
EcoMaint was tailored to meet ASIA DRAGON CORDAGE’s specific requirements. The system was integrated with the company’s existing SAP S/4HANA ERP system to enable seamless data flow between maintenance and production processes. Custom workflows were designed to accommodate the 24/7 production cycles of rope and fiber manufacturing, ensuring maintenance tasks did not disrupt operations.
3. Training and Onboarding
Vietsoft provided comprehensive training for ASIA DRAGON CORDAGE’s maintenance team and management. Training sessions, held at the company’s facility in Tân Tạo Industrial Park, covered system navigation, work order creation, spare parts management, and report generation. Hands-on exercises ensured that technicians could apply the software in real-world scenarios.
4. Pilot Phase
The implementation started with a pilot phase focusing on critical equipment, such as the Sima extrusion lines and Dea Young winding machines. During the first month, the pilot phase reduced equipment downtime by 12%, demonstrating the system’s potential. Feedback from the maintenance team was used to fine-tune configurations before the full rollout.
5. Full Rollout
Following the pilot’s success, EcoMaint was deployed across the entire production facility. Vietsoft provided dedicated support during the rollout, addressing technical issues and ensuring system stability. By September 2018, the system was fully operational, with all assets integrated into the platform.
6. Evaluation and Optimization
Six months after the full rollout, Vietsoft and ASIA DRAGON CORDAGE conducted a joint evaluation to assess the implementation’s impact. Key metrics included a 15% reduction in downtime, a 10% decrease in maintenance costs, and improved technician productivity. Based on the evaluation, minor adjustments were made to optimize workflows and enhance reporting capabilities.
By September 2018, the system was fully operational, and ASIA DRAGON CORDAGE reported significant improvements in maintenance efficiency. The company’s leadership, led by Ms. Nguyễn Việt Hòa, noted that the system’s transparency and streamlined processes empowered the team to take proactive measures, reducing downtime and enhancing productivity.
VII. Challenges and Solutions
Like any digital transformation project, the implementation faced challenges, including:
- Data Standardization: Integrating legacy data into EcoMaint required standardizing equipment records. Vietsoft’s team worked closely with ASIA DRAGON CORDAGE to clean and organize data, ensuring accuracy.
- User Adoption: Some employees were initially hesitant to adopt a new system. Vietsoft addressed this by providing hands-on training and ongoing support, helping the team embrace the technology.
- Customization Needs: ASIA DRAGON CORDAGE required specific workflows tailored to its production environment. Vietsoft customized EcoMaint to align with the company’s unique requirements, such as tracking maintenance for high-tech machinery.
VIII. How EcoMaint Supports ASIA DRAGON CORDAGE’s Growth Strategy
ASIA DRAGON CORDAGE implementing the CMMS software aligns with the company’s broader digital transformation strategy, which includes previous investments in ERP (SAP S/4HANA) and CRM (Salesforce). By integrating EcoMaint into its operations, ASIA DRAGON CORDAGE has strengthened its foundation for sustainable growth. The system supports the company’s goals of:
- Maintaining Market Leadership: By ensuring equipment reliability, EcoMaint helps ASIA DRAGON CORDAGE maintain its position as a top supplier in competitive markets.
- Expanding Product Lines: The scalability of EcoMaint supports the company’s plans to introduce new products, such as polyester straps for telecommunications and construction.
- Enhancing Customer Satisfaction: Reliable production processes ensure consistent product quality, reinforcing trust with international clients.
- Empowering the Workforce: The system’s user-friendly interface and mobile accessibility empower technicians to work more efficiently, fostering a culture of innovation and accountability.
IX. Conclusion: A Model for Manufacturing Excellence
ASIA DRAGON CORDAGE’s adoption of the EcoMaint CMMS solution represents a landmark achievement in its pursuit of operational excellence. By harnessing Vietsoft’s innovative software, the company is well-positioned to boost productivity, minimize costs, and solidify its standing as a premier manufacturer of ropes and synthetic fibers. This initiative sets a benchmark for other FDI and Vietnamese enterprises aiming to leverage digital tools for superior asset management.
For businesses eager to streamline maintenance and enhance operational efficiency, EcoMaint delivers a reliable, scalable solution tailored to modern manufacturing needs. Discover the CMMS EcoMaint solution here. Contact us for consultation via hotline: 0986778578 or email: sales@vietsoft.com.vn.
Join ASIA DRAGON CORDAGE and Vietsoft in shaping the future of manufacturing excellence!
