How Synergy Flavors is Building a Smarter, Future-Ready Maintenance Operation with MaintainX

Key results

• Reduced downtime by 90% on critical production equipment in just 13 weeks
• Achieved a 99.8% work order completion rate across 4,600 annual work orders
• Reduced mean time to repair (MTTR) by 48%
• Maintained 100% budget compliance since implementing MaintainX

Operational excellence isn’t just a goal at Synergy Flavours, it’s a mindset. Supporting a 200,000-square-foot manufacturing facility that spans production, R&D labs, and office space requires a highly coordinated, efficient approach powered by the right tools and systems.

Recognizing an opportunity to elevate performance and scalability, the maintenance team, led by Maintenance Supervisor Neal Perdkiri, took a proactive step toward digital transformation with MaintainX. The objective was clear: empower teams with real-time data, improve visibility across operations, and build a more agile, future-ready maintenance strategy.

Synergy has successfully digitized over 4,600 annual work orders since implementing MaintainX, achieving a 99.8% completion rate on those work orders while significantly improving responsiveness and reliability. The result was a 90% reduction in downtime on critical equipment and a 48% decrease in MTTR, unlocking greater production efficiency and operational consistency.

MaintainX has also provided the foundation for sustained performance and smarter decision-making, enabling the team to maintain full budget compliance while planning more strategically for the future.

Why MaintainX

Real-time execution from anywhere

Synergy prioritized a platform that could seamlessly connect fieldwork with operational oversight. MaintainX’s mobile-first design allows technicians to access and complete work orders directly at the point of activity, capturing photos, scanning QR codes, and tracking actual time spent on work orders.

Ease of use drove rapid adoption across the team, ensuring consistent engagement and accurate data capture across all experience levels.

Structured workflows for consistency and insight

Synergy leveraged MaintainX’s customizable workflows and logic-based triggers to support standardization and compliance. These features ensure that every task is completed thoroughly, with required steps automatically enforced when needed.

This approach not only strengthens execution, but also builds a reliable dataset that supports reporting, audits, and continuous improvement initiatives.

Scalable across teams

From the outset, Synergy saw value in a platform that could extend beyond maintenance. MaintainX has enabled stronger alignment across departments by creating shared visibility into work and performance. Its intuitive, visual interface has supported full adoption and improved coordination across teams. 

“Giving technicians immediate access to asset history and documentation has significantly reduced troubleshooting time,” Neal said. “They can make informed decisions on the spot instead of spending time tracking down information.” 

Results

Data-driven decisions that improve reliability

Synergy can identify trends and act quickly with enhanced visibility into equipment performance. Insights captured through MaintainX have enabled more informed decisions around asset management and reliability strategies, contributing to a 90% reduction in downtime on critical equipment in just 13 weeks.

Smarter resource and cost management

Access to real-time and historical data has allowed the team to optimize maintenance strategies, reducing unnecessary parts usage and improving inventory control. This shift toward a more proactive reliability model has been key to maintaining consistent budget performance.

Faster, more effective repairs

Technicians now have instant access to asset history, manuals, and prior work orders through a centralized digital system. This visibility has significantly reduced time spent searching for information and enabled faster, more accurate repairs, driving a 48% reduction in MTTR.

Streamlined compliance and audit readiness

With all work documented and easily searchable, audits are faster and more efficient. The ability to quickly filter and retrieve records ensures that compliance is always within reach.

Real-time visibility across operations

Live updates, start/stop tracking, and built-in communication tools provide complete transparency into maintenance activities. This has improved coordination across shifts and departments, contributing to a best-in-class 99.8% work order completion rate.

What’s next

Synergy Flavors continues to invest in the future of its maintenance operations. The team is currently developing an OT network to integrate MaintainX with its Ignition platform, enabling real-time sensor data to automatically trigger work orders based on actual equipment conditions.

This next step will further enhance predictive maintenance capabilities, allowing the team to anticipate issues before they impact operations. 

“We are building the network today to power the future,” Neal said. “By connecting MaintainX with Ignition, we’re moving beyond reactive maintenance to a truly predictive, data-driven operation.

Synergy’s approach reflects its broader commitment to innovation, efficiency, and continuous improvement. By leveraging MaintainX as a strategic platform, the company is not only optimizing current performance but also building a smarter, more resilient operation for the future.