Case Study – Enabling Smart Maintenance Operations in Automotive Component Manufacturing
Customer Profile
One of top 10 Automotive component manufacturer in India
Manufacturing facilities in 10 countries across 3 continents
5 Business verticals/units
Revenue of over $1.5 Billion
The Problems
Paper based manual operations
Redundant and time consuming
High amount of paper trail
Ineffective Maintenance Tracking
Missing critical maintenance schedules
Results in costly breakdowns
Lower productivity
Lack of seamless interdepartmental communications
Delayed response to breakdown
Higher equipment downtimes
Inaccurate records/reports
Lack of collaboration
Inefficient data accessibility and lack of history data
Data inaccuracies due to paper based operations
Time consuming to search for old data
No spare parts Tracking
Excess spares usage resulting in higher production cost
Unavailability of critical spare parts causing costly production delays
No data analysis
Available data cannot be used to make operations better
Cannot perform root cause analysis in case of any failure
No data visualizations and informed insights out of data
Solution
Predictive Maintenance
Condition Monitoring
Preventive Maintenance Schedules
Digital Maintenance Management Solution
Spare Parts Tracking
KPIs & Real-Time Dashboards
Complete digitization of maintenace activities
Mobile first software which enables plant technicians to access and input maintenance data from the field itself
Seamless integration with ERP systems. Maintenance data can be recorded with vMaint mobile or web application, which gets synced with ERP
Make operations Paper Less. Remove all
paper based work-flows & transactions
Brings in real time visibility into the maintenance operations, providing insights that help in making more informed decisions
Benefits
Paperless maintenance
PM scheduling, work orders and checklists are digitized. This has reduced the paper trail in the plant by 35%. It has eliminated the need to input all data in Excel one by one.
Real time tracking
Digitization of maintenance tasks enabled tracking metrics like overdue tasks, time taken to complete tasks, overtime duration at equipment as well as individual level. This has helped in gauging the performance of maintenance teams and identify areas of improvement.
PM Compliance
Automated notifications for due work orders ensure critical maintenance tasks are not missed. This has drastically reduced equipment failure and in turn increased reliability
Faster response to breakdown
Production personnel can quickly and accurately inform maintenance department of any breakdown by raising alerts using vMaint mobile application. This has improved the communication between the production and maintenance teams, enabled maintenance teams to swiftly address the issues and in turn reduce equipment downtime.
Spare Parts Tracking
Spare parts and inventory can be optimized to reduce holding costs while ensuring optimum inventory in case of maintenance requirement
Historical Data Access
Maintenance teams are able to access historical data on a single platform. Maintenance team is able to present past data to auditors accurately and at a faster rate, eliminating the need to preserve log books for auditing
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Case Study Customer Profile Pioneer in Adhesive technologies Headquartered in Europe with Annual revenue over 20 Billion USD Well established
