Maximize Uptime. Eliminate Breakdowns.

Equipment Registry — your single source of asset truth

Everything starts with knowing what you own. The equipment registry holds every asset that matters, organised in a parent-child hierarchy: Plant → Line → Machine → Component → Sub-component. Each asset carries its specifications, OEM, year of installation, warranty, criticality classification, location, custodian, and a complete maintenance history. A four-tab register dialog captures General details, Technical Specifications, Maintenance plan linkages, and Documents (manuals, drawings, spares lists, calibration certificates). Health monitoring percentages, MTBF and MTTR are computed and updated automatically from work-order data. Criticality is colour-coded — A, B, C — so the planner instantly sees where to focus.

Preventive Maintenance — turn breakdowns into a planned event

The PM module supports time-based (every 90 days), meter-based (every 2,000 running hours, every 50,000 strokes), and condition-based (vibration above 4.5 mm/s, temperature above 75°C) maintenance. Each PM is anchored to a maintenance plan with a checklist template, estimated duration, required spares, required skills, and expected downtime window. The schedule view is calendar-based and drag-friendly, allowing the planner to balance load across technicians and across machines. Overdue PMs are escalated visually and through email/WhatsApp alerts. PM compliance percentage is one of the headline KPIs on the maintenance dashboard.

Reactive Maintenance — when things still go wrong

No matter how good your PM is, breakdowns happen. The Reactive Maintenance screen lets any operator raise a breakdown report from a tablet on the line, capturing time of failure, machine, observed symptom, and a photo. The system classifies the failure type (mechanical, electrical, hydraulic, pneumatic, software, other), assigns severity (line-stop, partial-stop, quality-affecting, no-impact), and routes it to the right technician based on skill and shift. A six-step workflow — Reported, Acknowledged, Diagnosis, Repair, Verification, Closed — keeps everyone aligned. Root cause analysis is mandatory at closure for category-A failures, feeding back into the PM plan so that the same failure is less likely to recur.

Work Orders — the unit of execution

Whether the work is preventive, corrective or predictive, it is executed through a unified Work Order. Each WO carries the asset, the type of work, the priority, the assigned technician, the required spares (which are reserved against stores stock), the estimated and actual hours, the cost, and the closing notes. Mobile-friendly screens let the technician update progress, attach photos, capture meter readings and consume spares — all from the shop floor, without paperwork. Supervisors get a live Kanban view of work in progress, queued and overdue.

Checklists — institutional knowledge captured

Inspection templates standardise what needs to be checked during a PM or after a repair. Each task is one of three types — Check (yes/no/NA), Measure (numeric with min-max specification range and unit), or Observe (free-text observation with photo). Templates can be cloned, versioned and approved, ensuring that the technique your most experienced engineer uses to inspect a critical pump is the same technique used by every technician across the group. This is the kind of knowledge transfer that survives retirements and resignations.

Spare Parts — MRO inventory as a strategic asset

Maintenance, Repair and Operations inventory is its own discipline. The spare parts register tracks every spare with its asset linkage, current stock, reorder point, maximum, lead time, alternative spares, suppliers, and last consumption rate. Critical spares for A-class assets are flagged separately, with their own dashboards and stricter reorder controls. Stock valuation, slow-moving analysis and dead stock identification feed the CFO’s working capital review. Integration with the procurement module means a stock-out on a spare automatically triggers a purchase requisition with the right urgency.

Maintenance Dashboard — the KPI cockpit

The dashboard is built around the metrics that matter to a plant head and a CXO: Overall Equipment Effectiveness (OEE), Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR), PM compliance percentage, uptime percentage, work-order backlog, and cost per produced unit. Trend charts show downtime patterns over time; a Pareto chart of equipment downtime focuses improvement effort on the 20% of assets causing 80% of the loss; a work-order mix pie shows the balance of preventive versus reactive work; technician performance dashboards keep the team accountable.