{"id":29242,"date":"2025-04-02T12:13:28","date_gmt":"2025-04-02T18:13:28","guid":{"rendered":"https:\/\/limblecmms.com\/?post_type=customer-story&p=29242"},"modified":"2025-07-07T11:20:15","modified_gmt":"2025-07-07T17:20:15","slug":"polyexcel","status":"publish","type":"customer-story","link":"https:\/\/limblecmms.com\/customer-story\/polyexcel\/","title":{"rendered":"PolyExcel"},"content":{"rendered":"\n
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Introduction<\/h2>\n\n\n\n

Utah-based PolyExcel takes pride in manufacturing high-quality twines for various industries. The organization\u2019s satisfied customers include mostly agribusinesses and construction companies. They count on PolyExcel for durable twines and cords that meet strict standards of excellence and enable them to carry out daily operations.<\/p>\n\n\n\n

A team of three maintenance managers oversees technicians across PolyExcel\u2019s facilities. According to, Darwin Knight, who co-directs the company\u2019s maintenance department, they don\u2019t lead from desks, instead taking a hands-on approach to maintaining PolyExcel\u2019s extrusion equipment and other critical assets.<\/p>\n\n\n\n

These aren\u2019t simple machines, nor is melting plastic into cordage a simple production process. The folks at PolyExcel have a lot of physics and chemistry challenges on their minds. They required a solution to streamline any parts of their job that can be streamlined, allow for more robust data analysis, and enable efficiencies to help them thrive despite ongoing workforce shortages.<\/p>\n<\/div><\/div>\n\n\n\n

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The Challenge<\/h2>\n\n\n\n

Workforce shortages topped the list of challenges in Limble\u2019s recent survey of maintenance professionals<\/a> in the facilities management and manufacturing sectors. The COVID-19 pandemic exacerbated what was already a growing concern for hiring teams and managers across the space, leaving nearly 1.5 million jobs open. By 2030, the Manufacturing Institute and Deloitte predict that a lack of available skilled labor will leave companies scrambling to staff an additional 2.1 million positions<\/a>.<\/p>\n\n\n\n

Almost 70% of manufacturers surveyed agreed that their industry is facing a skills shortage. Answers varied, however, as to the primary cause of the trouble. Respondents cited issues ranging from a lack of interest among young people to insufficient opportunities for learning the right skills in school. PolyExcel found themselves among the 34% of manufacturers who cite retiring baby boomers as their biggest workforce challenge. Knight says that an outgoing \u201ccache of legacy knowledge\u201d was what inspired him to start reviewing CMMS platforms in the first place. The organization simply could not allow decades of best practices and hard-won industry insight to disappear.<\/strong><\/p>\n\n\n\n\n

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\u201cIt used to take us hours to prepare for a shutdown. Not anymore. The tasks related to shutdowns are easily replicated, put onto dashboards, and assigned to personnel so that they get taken care of.\u201d<\/h6><\/div>\n
\n Darwin KnightCo-Director of Maintenance<\/span><\/span>\n <\/div>\n <\/div>\n
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Limble\u2019s features for parts inventory management and data analysis made it stand out as a potential game-changer. Prior to implementing the award-winning CMMS, Knight says, \u201cWe had never taken an inventory before.\u201d Data analysis was seriously lacking pre-Limble as well. PolyExcel knew what it was ordering and what it had on hand, but they weren\u2019t able to analyze asset performance and ordering histories in a way that helped them plan maintenance activities around production requirements.<\/p>\n\n\n\n

This lack of insight resulted in plenty of confusion and wasted time. Technicians sometimes took days to address breakdowns and managers lacked the means for tracking performance or promoting accountability. With retirements looming and the daily challenges of legacy processes continuing to grow, PolyExcel recognized that investing in technology like a CMMS could no longer wait.<\/p>\n<\/div><\/div>\n\n\n\n

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The Solution<\/h2>\n\n\n\n

Limble stood out from the competition thanks to its ease of use and implementation. Knight needed something he could trust his technicians to actually use. Additional complexity would only cause new problems.<\/p>\n\n\n\n

The PolyExcel team got started with a pilot program, introducing Limble for a small number of their most critical assets. Throughout the process, Limble\u2019s team offered a range of options to suit PolyExcel\u2019s needs.<\/p>\n\n\n\n

The trial run was a huge success. They\u2019ve since started rolling out Limble to the rest of the organization. As they continue to reap the benefits of more efficient, data-driven maintenance, they\u2019ll continue evolving the way they apply Limble to ensure they thrive in a new era.<\/p>\n\n\n\n\n

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\u201cLimble has allowed us to take individual pieces of data and turn them into real information. We don’t go into a meeting anymore and say, I think, and I feel. We say, I know.\u201d<\/h6><\/div>\n
\n Darwin KnightCo-Director of Maintenance<\/span><\/span>\n <\/div>\n <\/div>\n
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The Result<\/h2>\n\n\n\n

PolyExcel is still fairly early in its relationship with Limble. They are, however, already seeing impressive improvements. When it comes to efficiency, Knight estimates that PolyExcel has \u201ccut walk-around time by half.\u201d<\/p>\n\n\n\n

Though there\u2019s work still to come, PolyExcel can credit Limble with totally overhauling its maintenance function. As Knight puts it, the difference is already \u201cnight and day.\u201d Whatever the future brings, PolyExcel knows they have an ally in Limble. Knight notes that choosing Limble has meant more than access to a great product. He says he would recommend Limble\u2019s people just as highly as its platform.<\/p>\n\n\n\n

Custom workflows and handy templates<\/h3>\n\n\n\n

New custom task lists for specific types of breakdowns and downtime-causing events help PolyExcel prioritize work effectively. \u201cIt used to take us hours and hours to prepare for a shutdown,\u201d Knight remarks, \u201cnot anymore.\u201d PolyExcel\u2019s maintenance department now has plans of action at the ready whenever key assets break down. Problems that once produced hours or days of chaos are now managed with ease.<\/p>\n\n\n\n

Usability was among PolyExcel\u2019s top priorities when reviewing CMMS platforms. Knight calls it his number-one must-have and confirms that Limble has more than met his needs. Without the need to learn complicated new systems, his team can access Limble on the go to ensure they quickly execute tasks. When a work order calls for something new or complicated, it\u2019s simple to find detailed instructions and keep extrusion equipment in top condition.<\/p>\n\n\n\n

Bringing a plant that\u2019s operated one way for almost 40 years into a tech-enabled future was never going to be simple. That said, PolyExcel\u2019s team credits the Limble team with making implementation and adoption as smooth as possible. \u201cLimble has been there every step of the way,\u201d says Knight. Best of all, Limble has emphasized flexibility throughout the entire engagement. Rather than force PolyExcel down a prescribed path for maintenance transformation, they\u2019ve \u201cprovided us with multiple solutions that have made it work for us.\u201d<\/p>\n\n\n\n\n

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\u201cIt’s much more than a partnership. We absolutely depend on Limble.\u201d<\/h6><\/div>\n
\n Darwin KnightCo-Director of Maintenance<\/span><\/span>\n <\/div>\n <\/div>\n
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Entering a new era of efficiency<\/h3>\n\n\n\n

For PolyExcel, transitioning to a modern, cloud-based CMMS platform was nothing short of a transformation. Knight jokes that clipboards and pens were among the most advanced tools his team used to manage maintenance tasks. When it comes to parts inventory management, the team had historically taken a \u201ccoffee can\u201d approach. Though the team knew which parts they had on hand, they rarely had the right part at the ready. Instead, they searched and searched, leaving equipment out of commission and leaving output and revenue on the table.<\/p>\n\n\n\n

Access to data has empowered PolyExcel\u2019s maintenance team to reach a new standard of excellence that demonstrates the pride they take in their work and the quality of their products. \u201cLimble has allowed us to take data and turn it into real information,\u201d said Knight. This enables the maintenance team to operate with more confidence, make more informed decisions, and advocate for the resources it needs. Knight continues, \u201cWe don\u2019t go into a meeting anymore and say, \u2018I think\u2019 or \u2018I feel,\u2019 we say \u2018I know.\u2019\u201d Knight can tie maintenance work to a verifiable ROI and show that the function is worth trusting as more than a tactical cost center<\/p>\n\n\n\n

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\n \"Icon\"\n <\/div>\n

\n 50% <\/h3>\n

\n Reduction in "Walk Around Time" <\/p>\n <\/div>\n <\/div>\n

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\n \"Icon\"\n <\/div>\n

\n 90% <\/h3>\n

\n Improvement in Parts Inventory Accuracy <\/p>\n <\/div>\n <\/div>\n

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\n \"Icon\"\n <\/div>\n

\n 30% <\/h3>\n

\n Decrease in Mean Time to Recovery <\/p>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/blockquote>\n\n\n\n

Equipping the next generation<\/h3>\n\n\n\n

Among Deloitte\u2019s recommendations for addressing manufacturing\u2019s talent shortages is a call to \u201ccreate pathways to tomorrow\u2019s jobs today.\u201d Implementing the right time- and headache-saving technology has done just that for PolyExcel.<\/p>\n\n\n\n

They knew there were shifting attitudes and expectations across the workforce. Incoming employees won\u2019t thrive or even stick around if they think their organization is stuck in the past.<\/p>\n\n\n\n

\u201cTo the credit of the folks that have worked here, they have made it work for a long time,\u201d says Knight. He recognizes, however, that it\u2019s not realistic to expect incoming employees to excel under the same circumstances. And they can\u2019t afford to view decades of experience as a hiring prerequisite in the current labor market.<\/p>\n\n\n\n

Fortunately, the next generation of PolyExcel employees won\u2019t need to spend decades or even years with the company to take advantage of all the lessons the organization\u2019s maintenance and facilities professionals have learned. They\u2019ll instead hit the ground running thanks to a single source of essential data, documents, and training resources.<\/p>\n\n\n\n\n

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\u201cLimble is a very solid pillar of our organization.\u201d<\/h6><\/div>\n
\n Darwin KnightCo-Director of Maintenance<\/span><\/span>\n <\/div>\n <\/div>\n
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Flexibility and vision for the future<\/h3>\n\n\n\n

For the team at PolyExcel, Limble is more than a partner. \u201cA partner,\u201d said Knight, \u201cmay get sick or decide to go fishing. Limble is there all the time, always delivering exactly what we need them to deliver.\u201d<\/p>\n\n\n\n

More than anything, Limble has given PolyExcel a number of options for writing its next chapter. \u201cThat\u2019s what we didn\u2019t have before,\u201d says Knight, \u201coptions.\u201d With more data at its disposal and the ongoing support of the Limble team, the maintenance team will continue to evolve and grow.<\/p>\n<\/div><\/div>\n<\/div>\n<\/div>\n","protected":false},"featured_media":25063,"template":"","industry":[709],"use-case":[],"class_list":["post-29242","customer-story","type-customer-story","status-publish","has-post-thumbnail","hentry","industry-manufacturing"],"acf":[],"yoast_head":"\nPolyExcel Tackles Workforce and Reporting Challenges | Limble<\/title>\n<meta name=\"description\" content=\"PolyExcel, a go-to manufacturer for numerous industries, trusts Limble to close skills gaps and transform maintenance reporting. 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