How can maintenance operations be effectively managed in a cable manufacturing plant where machines operate according to different schedules and production data is collected in a Manufacturing Execution System (MES)?
This was the challenge faced by the LEONI Cable Solutions team. The solution was the implementation of the Profesal Maintenance CMMS, integrated with the MES and enhanced with functionalities tailored to the plant’s actual production environment.
The project included, among other features, automatic calculation of MTTR, MTBF and machine technical availability, individual equipment operating schedules, interactive maintenance checklists, and dedicated reporting.
In this case study, we present the challenges, objectives and implementation process, as well as the solutions deployed at the LEONI Kabel Polska plant in Wierzbice.
Table of contents
LEONI Cable Solutions – a global cable manufacturer
LEONI Kabel Polska Sp. z o.o. operates in Wierzbice near Kobierzyce and is part of the global LEONI Cable Solutions Group, a supplier of wiring systems.
The plant manufactures cables used in vehicles produced by global automotive brands. In 2026, the company celebrated 25 years of operations in Poland. The LEONI Cable Solutions Group operates manufacturing plants in several countries, including Poland, Germany, Mexico, Hungary, Slovakia, Turkey and China.
The nature of cable manufacturing requires reliable machinery operation, effective maintenance planning and access to accurate equipment data. The ability to analyse maintenance KPIs based on the actual production setup also plays an important role.
These requirements formed the basis for the implementation of the Profesal Maintenance system.
Key information about the CMMS implementation
| Area | Details |
| Client | LEONI Kabel Polska Sp. z o.o. |
| Group | LEONI Cable Solutions |
| Industry | Cable and wiring systems manufacturing |
| System | Profesal Maintenance |
| Additional applications | Profesal Mobile, mySupport |
| Project objective | Automation of maintenance KPIs and adaptation of the system to the plant’s production environment |
| Integration | MES |
| KPIs | MTTR, MTBF, technical availability |
| Custom solutions | Machine operating schedules, interactive checklists, reporting |
The implementation went beyond deploying the standard functionalities of a CMMS. Profesal Maintenance was enhanced with solutions tailored to the requirements of the maintenance department and the specific production processes of the plant.
Maintenance Challenges at LEONI Cable Solutions
LEONI Cable Solutions had previous experience with CMMS solutions. The client’s team therefore entered the project with clearly defined expectations regarding functionality, reporting and data processing.
The key challenge was not simply to digitise maintenance documentation, but to develop a solution that would enable reliable analysis of machine performance while taking individual production schedules into account.
Automatic Calculation of MTTR, MTBF and Machine Availability
One of the key requirements was to automate the calculation of three maintenance KPIs:
- MTTR (Mean Time To Repair) – the average time required to repair a machine.
- MTBF (Mean Time Between Failures) – the average operating time between failures.
- Technical availability – a KPI indicating a machine’s readiness for operation during the analysed period.
Individual machines at the plant may operate according to different schedules. Using a single standard calendar as the basis for calculations would not accurately reflect the actual production setup.
The new system therefore had to take into account the planned operating time of individual machines as well as production shift schedules.
CMMS Integration with MES
Another key challenge was integrating the maintenance management system with the MES (Manufacturing Execution System) used at the plant.
The objective was to automatically retrieve machine operating data and equipment meter readings.
This integration enables production data to be used in maintenance processes without the need to manually transfer information between systems.
Enhancement of the Existing CMMS Environment
The CMMS previously used by LEONI Cable Solutions did not provide all the required functionalities.
In particular, it lacked interactive maintenance checklists and reports tailored to the plant’s specific needs.
The new solution had to support the execution of defined maintenance procedures and enable analyses aligned with the requirements of the maintenance department.
CMMS Implementation Objectives
The main objective of the project was to create an integrated maintenance management environment based on reliable machine operating and production process data.
The implementation of Profesal Maintenance was intended to provide:
- Automatic calculation of MTTR, MTBF and technical availability.
- Consideration of the planned operating time of individual machines.
- Support for individual machine schedules and production shifts.
- Integration of the CMMS with the MES and automatic data retrieval.
- Use of machine meter readings.
- Digitalisation of maintenance inspections using interactive checklists.
- Reporting tailored to the plant’s requirements.
- Mobile access to maintenance processes.
- User support through the mySupport application.
Achieving these objectives required both the implementation of the system and the adaptation of its functionalities to the company’s existing operational processes.
How Was the Profesal Maintenance CMMS Implemented?
At LEONI Cable Solutions, the Profesal Maintenance CMMS was implemented together with the Profesal Mobile and mySupport applications. The solution was deployed for the Maintenance Department.
The project was carried out with the active involvement of the client’s team. Thanks to the employees’ previous experience with CMMS solutions, it was possible to precisely define the requirements and identify the areas that needed to be adapted.
Individual Machine Operating Schedules
One of the key elements of the implementation was the development of a mechanism that considers individual machine operating schedules and production shifts.
Individual machines may operate according to different schedules. Therefore, calculating maintenance KPIs required moving away from a single, simplified reference time.
The implemented solution allows calculations to be based on the planned operating time of individual machines.
Implementation outcome: maintenance KPIs can be calculated automatically based on schedules that reflect the plant’s actual operating conditions.
Automatic Calculation of MTTR, MTBF and Technical Availability
Profesal Maintenance was enhanced with mechanisms for the automatic calculation of key maintenance KPIs.
The system enables the analysis of Mean Time To Repair (MTTR), Mean Time Between Failures (MTBF), and equipment technical availability.
For LEONI Cable Solutions, it was particularly important to link these calculations to the planned operating time of individual machines.
As a result, the calculated KPIs are based on the actual schedules used at the plant rather than on a single standard calendar.
Implementation outcome: greater alignment of maintenance analyses with the plant’s actual production setup.
Integration of Profesal Maintenance with the MES
As part of the project, Profesal Maintenance was integrated with the MES used by LEONI Cable Solutions.
Integration enables the automatic retrieval of two types of information:
- Machine operating data.
- Equipment meter readings.
This information can then be used in maintenance processes managed within the CMMS.
Integration reduces the need to manually enter data that is already available within the production environment.
Implementation outcome: integration of production data with the information used by the maintenance department.
Interactive Maintenance Checklists
Another element of the project was the implementation of interactive maintenance checklists.
This functionality was not available in the CMMS previously used by the client.
The checklists guide users through the individual tasks required during a maintenance inspection, while enabling the completed activities to be documented in a standardised format.
The solution supports the execution of maintenance procedures and helps organise information on completed maintenance activities.
Implementation outcome: standardised execution and documentation of maintenance inspections.
Dedicated Maintenance Reporting
The implementation also included the development of reports tailored to the specific needs of LEONI Cable Solutions.
The implementation also included the development of reports tailored to the specific needs of LEONI Cable Solutions.
The reports use data that considers planned machine operating times as well as information retrieved from the MES.
Implementation outcome: access to analyses tailored to the requirements of the Maintenance Department.
CMMS Implementation Results at LEONI Cable Solutions
The implementation of Profesal Maintenance enhanced the maintenance management environment with functionalities tailored to the needs of the manufacturing plant.
The key project outcomes are presented below.
| Challenge | Implemented Solution | Outcome |
| Different machine operating schedules | Individual machine operating calendars | Planned operating time considered in KPI calculations |
| Need for KPI automation | Mechanisms for calculating MTTR, MTBF and technical availability | Automatic KPI calculation |
| Data available in the MES | CMMS integration with MES | Automatic retrieval of machine data and meter readings |
| Lack of interactive checklists | Digital maintenance checklists | Standardised execution and documentation of maintenance inspections |
| Insufficient reporting capabilities | Dedicated reports | Analyses tailored to the plant’s requirements |
| Need to adapt the system | Enhancement of Profesal Maintenance | Functionalities tailored to the client’s processes |
Another important element of the implementation was the cooperation with the experienced LEONI Cable Solutions team.
The involvement of the client’s employees in defining the requirements made it possible to tailor the system to specific processes rather than limiting the project to a standard software configuration.
CMMS in the Cable Industry: Profesal’s Experience
The CMMS implementation at LEONI Cable Solutions is another example of how Profesal Maintenance is used by companies involved in the production of cables and wiring systems.
The solution had previously also been implemented at HELUKABEL and Voltrim Trade.
At HELUKABEL, the system supports, among other areas, machine and spare parts management, service activities and preventive maintenance.
See: Case Study: CMMS Implementation at HELUKABEL.
At Voltrim Trade, a Polish manufacturer of electrical cables, the implementation included machine and spare parts records, tracking technicians’ activities and support for preventive maintenance planning.
See: Case Study: CMMS Implementation at Voltrim Trade.
The projects completed by LEONI Cable Solutions, HELUKABEL and Voltrim Trade demonstrate how maintenance requirements can vary between companies operating in the same industry.
At one plant, the priority may be to organise machine and spare parts records, while at another it may be to develop preventive maintenance activities. Elsewhere, the focus may be on integration with production systems and the automation of maintenance KPI calculations.
The ability to adapt CMMS functionalities to a company’s actual processes is therefore a key element of Profesal Maintenance implementations.
CMMS Implementation from the LEONI Cable Solutions Perspective
An important aspect of the project was close cooperation with the client’s team, which already had previous experience with CMMS solutions.
“Based on our previous experience with CMMS solutions, we entered the project with clearly defined expectations regarding the required functionalities and how the system should operate. One of our key requirements was to correctly account for planned machine operating time when automatically calculating maintenance KPIs and to adapt the system to the actual production setup.”
Klaudia Sperczyńska
Manager Maintenance
“The project was carried out with the active involvement of our team, which allowed us to precisely identify the areas requiring adaptation. As a result of this cooperation, Profesal Maintenance was enhanced with solutions tailored to the plant’s needs, particularly in terms of automatic KPI calculation, interactive maintenance checklists and dedicated reporting.”
Piotr Ochenduszkiewicz
Managing Director
FAQ: Frequently Asked Questions About the CMMS Implementation at LEONI Cable Solutions
Why did LEONI Cable Solutions decide to implement Profesal Maintenance?
The company needed a system that met the requirements of the Maintenance Department. Key priorities included the automatic calculation of MTTR, MTBF and machine technical availability, support for individual machine operating schedules, and enhanced maintenance inspection and reporting functionalities.
Which systems and applications were included in the implementation?
The project included the implementation of the Profesal Maintenance CMMS together with the Profesal Mobile and mySupport applications. The CMMS was also integrated with the MES used at the plant.
What are the benefits of integrating the CMMS with the MES?
The integration enables the automatic retrieval of machine operating data and equipment meter readings. This information can be used in maintenance processes, reducing the need to manually transfer data between systems.
How does the CMMS calculate MTTR and MTBF?
Profesal Maintenance automates the calculation of MTTR and MTBF. In the LEONI Cable Solutions project, the calculation mechanisms were adapted to consider the planned operating time of individual machines and the plant’s production schedules.
Why are individual machine operating schedules important?
Machines may operate according to different schedules. Taking the planned operating time of individual machines into account makes it possible to align calculated KPIs with the actual production setup instead of applying a single standard calendar to the entire machine park.
Did the implementation include digital maintenance checklists?
Yes. The project included interactive maintenance checklists that support the execution of defined maintenance tasks and the documentation of completed inspections. This functionality was not available in the client’s previous CMMS.
Was Profesal Maintenance customised to the needs of LEONI Cable Solutions?
Yes. The system was enhanced with mechanisms for automatic KPI calculation based on machine operating schedules, interactive maintenance checklists and dedicated reporting.
What role did the LEONI Cable Solutions team play in the project?
The client’s employees actively participated in defining requirements and identifying areas that required adaptation. Their previous experience with CMMS solutions made it possible to precisely define the expected functionalities.
Summary: How Does CMMS Support Maintenance in the Cable Industry?
The LEONI Cable Solutions case demonstrates that a CMMS implementation can go beyond basic failure reporting, equipment records and maintenance scheduling.
At the plant, solutions were implemented to automatically calculate MTTR, MTBF and technical availability while taking individual machine operating schedules into account.
Integration with the MES made it possible to use production data and equipment meter readings, while interactive checklists and dedicated reports expanded the range of maintenance processes supported digitally.
The project was carried out with the active involvement of the client’s team, and Profesal Maintenance was enhanced with functionalities tailored to the specific requirements of the Wierzbice plant.
Profesal Maintenance: CMMS for Manufacturing Plants
Profesal Maintenance is a CMMS that supports maintenance management, machine and equipment records, failure management, maintenance inspections, technical tasks and KPI monitoring.
The implementation at LEONI Cable Solutions demonstrates how the solution can be adapted to a company’s individual requirements, including integration with an MES, support for machine operating schedules and advanced reporting.
The scope of each project and the possibility of integration with the existing infrastructure require an analysis of the available data and the processes in place at the plant.
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