Plant Maintenance

Alongside breakdown and maintenance requests, orders can be raised as setup or changeover requests, so the work that prepares a machine for its next production run is planned and recorded in the same place as its repairs.

Reusable templates define the standard tasks, checklists, and resources required for recurring maintenance jobs, reducing the effort of creating Maintenance Orders from scratch. A template can also mark its asset as unavailable for production while the work is under way, so nothing is scheduled onto a machine that is on the bench.

Each Maintenance Order contains tasks and checkpoints that must be completed in sequence, providing a structured and documented record of the work carried out. Checkpoints can be checklist items, questions, quantitative or qualitative measurements, inspections, or meter readings.

Maintenance findings and meter readings are recorded against each order, building a history of asset condition over time. Completed inspection results can be reviewed and verified before an order is formally closed, and marked valid, invalid, or a discontinuity.

Orders close against structured problem, cause, failure, and action codes, so recurring failures can be analyzed across assets rather than being buried in free-text notes.

Additional sub work orders can be created for a Maintenance Order, supporting complex jobs that involve multiple tasks or teams. Many orders can also be moved from work request to released in a single step rather than one at a time.

Each Maintenance Order carries the spare parts and consumables it requires, with quantities, unit of measure, issue type, and the warehouse they are drawn from. Reusable Material List templates cover jobs that always need the same parts.

The tools a job depends on are listed alongside the materials with their expected usage hours, so shared tooling can be planned rather than discovered missing at the point of work.

Trades define the types of worker a task calls for, each with an hourly rate and required qualifications, so a Maintenance Order reflects both the skills it needs and what the labor will cost.

Planned maintenance schedules can be defined to trigger Maintenance Orders at fixed or variable time intervals, ensuring that routine maintenance is carried out consistently.

Preventive Maintenance Orders can be triggered by meter readings such as operating hours, cycles, or wear measurements, so maintenance is based on actual equipment condition rather than time alone.

When a schedule trigger is reached, Maintenance Orders can be generated automatically, so planned and preventive maintenance is never missed due to manual oversight.

Schedules can be defined as fixed, where the next trigger is calculated from a set interval, or variable, where the next trigger is based on the value recorded at the last maintenance closure.

Readings taken from the counters on the equipment itself are recorded as Meter Reading documents, entered either as an absolute reading or as the difference since the last one. Full reading history is available per meter.

An effective meter tracks cumulative usage independently of the physical counter, so resetting or replacing a counter does not lose an asset's running total. Readings can be inherited down the asset hierarchy, so the equipment beneath a parent asset accrues the usage recorded against it.

Maintenance operators can view, filter, and access their assigned Maintenance Orders, tasks, and checkpoints from a mobile device or tablet.

Meter readings, inspection findings, and task completions are recorded directly on the device at the point of maintenance, keeping records accurate and up to date.

Maintenance Order and task statuses can be updated from the mobile app, giving managers real-time visibility of progress without waiting for paper-based reports.

Photographs and supporting documents can be added to Maintenance Orders directly from the mobile app, providing visual evidence of maintenance findings.