The problem
Amcor Flexibles' plant in Nový Bydžov runs some of the most complex flexible packaging lines in Central Europe, producing film for coffee, pet food, and specialty packaging. The lines run continuously, so every unplanned stop costs money. When a machine failed, the maintenance team had one option: search through binders, call a senior engineer, or wait. Repairs took hours, not because the fix was technically hard, but because finding the right answer was.
Maintenance knowledge at Amcor sat in three places: hundreds of PDFs, handwritten logs, and the heads of technicians who had spent decades on the floor. None of it was searchable. A junior technician answering a fault alarm at 2 a.m. had no way to reach the institutional knowledge a seasoned engineer could recall in seconds, and there was no structured way to capture that knowledge before people retired.
