Complete CMMS solution for manufacturing plants

Aproduction manager at a food processing plant in Michigan received a frantic call at 3 AM—the main packaging line conveyor had seized completely. The belt, which had been showing subtle signs of edge fraying...

Amaintenance supervisor at a steel manufacturing plant in Ohio watched helplessly as a critical conveyor line ground to a halt. The culprit? A $47 bearing that had been showing warning signs for six...

A maintenance technician at a Texas manufacturing plant spent 15 minutes last Tuesday searching for the previous month's air compressor inspection records. He found them eventually—crumpled in a toolbox,...

The production line went silent at 2:47 AM. Your centrifugal pump—the one moving 500 gallons per minute through your cooling system—just failed. Emergency repair costs: $8,500. Lost production while waiting...

That conveyor motor runs 16 hours a day, every day. Right now, the bearings are developing micro-fractures you can't hear, see, or feel. In approximately six weeks, it will seize during peak production—halting...

A single missed inspection point cost a Michigan automotive parts manufacturer $127,000 last quarter. The gearbox bearing that failed had been making subtle noise changes for six weeks—changes that a...

The cement industry generates more operational data per hour than most manufacturing sectors combined—kiln temperatures cycling through 1,400°C pyroprocessing zones, raw mill vibration signatures across 500+...

Every 15 seconds, a worker somewhere in the world dies from a work-related accident or disease. In cement manufacturing, where workers navigate rotating kilns operating at 1,400°C, confined spaces inside silos...

Energy costs consume 30-40% of every dollar your cement plant spends on production—making fuel and electricity your largest controllable expense after raw materials. For a typical 2,000 TPD facility, that...

Somewhere in your plant right now, a bearing is failing. Not catastrophically—not yet. But deep within its metal housing, microscopic cracks are spreading, temperatures are rising fractionally, and vibration...

Your kiln is producing 2,000 tonnes of clinker daily, but you won't know if the last four hours of production meets quality standards until the lab results arrive. By then, you've either wasted fuel over-burning...

The call comes without warning. EPA Region 5 has scheduled a compliance inspection at your cement plant in 48 hours. Somewhere in this facility—across control room binders, legacy databases, filing cabinets in...

Right now, your cement mill is burning through electricity at a rate that would power 500 homes. Every hour, 3,500 kWh disappears into the grinding chamber—and physics dictates that 95% of that energy converts...

Picture this: Your cement plant produces 2,000 tons daily. Every 24 hours, you're betting $304,000 worth of product on test results you won't see for nearly a month. By Day 28, when lab results finally confirm a...

When your cement mill gearbox fails at 2 AM on a Saturday, the clock starts running at $100,000 per hour—and it doesn't stop until production resumes. Your maintenance team scrambles to diagnose a problem that...

Every hour your cement kiln sits idle, you're watching $12,500 to $100,000 evaporate into thin air. For a typical 1 MTPA cement plant, a single day of unplanned downtime translates to roughly $300,000 in lost...

Your rotary kiln operates at 1,450°C around the clock, consuming fuel that accounts for 20-30% of your total production costs. With fuel expenses running approximately $20 per ton of cement and national average...

A Pune automotive manufacturer invested ₹32 lakhs in on-premise AI for quality inspection in February 2024. By February 2025—exactly 12 months later—the system had saved ₹38  lakhs  in ...

A Pune automotive parts manufacturer started with a cloud AI pilot for quality inspection in January 2024. Budget: ₹15 lakhs monthly. By July, costs hit ₹62 lakhs—over 4x the original  estimate....

In 2023, global AI investment hit $252 billion. Yet 80% of AI projects fail before reaching production. For Indian manufacturers, this paradox is acute: massive investment, minimal success.  A Nashik food...

When a Pune automotive manufacturer deployed cloud AI for quality inspection in 2023, they expected transformation. Instead: 890ms latency that broke real-time control, ₹18L monthly costs, and system failure...

When a $50 million automotive parts manufacturer in Pune deployed a cloud-based AI vision system to detect paint defects on their assembly line, they expected 99.9% uptime and millisecond  response times....

2:47 PM. Your ISO auditor pulls calibration records for the pick-and-place machine that's been running production for three weeks. Last calibration: 94 days ago. Due date: 90 days. For four...

A textile plant maintenance supervisor receives three urgent calls within an hour: Ring spinning frame #4 showing excessive vibration, dyeing machine temperature controller malfunctioning mid-batch ($48,000...

A textile plant maintenance supervisor receives three urgent calls within an hour: Ring spinning frame #4 showing excessive vibration, dyeing machine temperature controller malfunctioning mid-batch ($48,000...

Your electronics assembly line runs at 62% OEE. Competitors implementing predictive maintenance hit 85%+—gaining 15-25% capacity advantage. Technology isn't the barrier—people are. Veterans resist sensors...

Your thermal camera shows a motor bearing at 185°F. Normal or emergency? Your vibration meter reads 0.35 in/sec on a pump. Acceptable or failure imminent? Without standardized troubleshooting criteria, the same...

Your packaging line stops at 2 AM. The filling machine seizes unexpectedly. Production scrambles to diagnose the problem while $45,000 worth of product sits in limbo. Six hours later, technicians discover a...

Picture this: Your critical pump fails again for the third time this year. Each failure costs $60,000 in repairs plus production downtime. Your team replaces seals, bearings, and impellers—but the failures...

Your electronics assembly line stops unexpectedly. The SMT machine throws  a cryptic error code. Production halts. Technicians scramble through paper logs trying to understand what happened. Meanwhile, the...

Your lubrication technician walks the plant every week with a grease gun and clipboard. Four hours later, he's greased 120 points. But here's the problem: 35% of those points didn't need lubrication yet. Another...

The plant manager reviews the quarterly board presentation with growing unease—Overall Equipment Effectiveness (OEE) sits at 58% while competitors achieve 75-85%, costing the operation $4.2 million annually in...

The cement plant maintenance director faces a frustrating reality: three months after implementing a $180,000 CMMS platform, technicians still carry paper clipboards, work orders pile up incomplete in the...

A chemical plant's monthly energy bill shows $840,000—within budget. Yet asset-level analysis reveals $2.3M annual waste: boilers consuming 18% excess gas, cooling towers drawing 22% extra power, pumps...

A beverage packaging line experiences the same bearing failure three times in five months—each costs $28,000 emergency repair plus $94,000 lost production (11-hour stoppage). After the third failure,...

The maintenance manager at a pharmaceutical manufacturing facility reviews last quarter's performance discovering a troubling pattern: $2.8M spent on maintenance yet unplanned downtime increased 12%, critical...

The maintenance supervisor reviews last month's lubrication records discovering three critical problems: technicians spent 42 hours performing lubrication rounds yet missed 18% of scheduled points, used $14,000...

The production manager walks the factory floor at 7:45 AM, clipboard in hand, asking line supervisors: "What's the status on Line 3's CNC machine?" "When was the last PM on the assembly robot?" "Which equipment...

The cement plant operations manager reviews the monthly energy report showing $847,000 in electricity costs—representing 38% of total production expenses—yet when asked which specific equipment drives...

The production manager receives the daily operations report showing 82% equipment effectiveness—a number that seems acceptable until the plant controller calculates lost production value: $147,000 this week...

The maintenance supervisor at a chemical processing facility stares at a clipboard stacked with 47 handwritten work orders—some dating back three weeks, half missing critical equipment data,  and none...

The electronics assembly facility manager reviews the quarterly audit report  with mounting concern—three IPC compliance findings related to inadequate predictive maintenance documentation, $340,000 in...

The textile plant manager stares at a production halt notice—the third this quarter—as a critical spinning frame bearing waits in a purchase order queue while $45,000 of daily production capacity sits idle....