Industrial Plant Operations
Minimize unscheduled downtime by 30-40% with real-time equipment monitoring, condition-based maintenance alerts, and predictive analytics. Reduce maintenance costs by 20-25% and ensure safety compliance.
Plant Operations Challenges
Plant operators face relentless pressure to maximize uptime, prevent costly failures, and maintain safety compliance while production demands never stop.
The $2.4M Production Line Failure
It's 2:15 AM and your phone is ringing. Production Line 3 is down—a critical pump failed catastrophically, spraying hydraulic fluid across the plant floor. The emergency shutdown halted production with $85K/hour in lost output. Maintenance tells you the pump showed warning signs for weeks—elevated vibration, rising temperature—but those readings were buried in spreadsheets nobody monitored. By the time you source parts and complete repairs, you'll lose 28 hours worth $2.4M.
The OSHA Compliance Nightmare
OSHA inspectors are on-site for a surprise audit asking for Lock-Out Tag-Out documentation, safety system inspection records, and pressure vessel certifications for the last 24 months. You're scrambling through filing cabinets trying to prove compliance. The safety interlock on Reactor 2 was due for testing 3 weeks ago but nobody caught it. The inspector finds expired certifications on two boilers and incomplete LOTO procedures. You're facing citations, fines, and possible shutdowns.
The Invisible Equipment Degradation
Your OEE has declined from 85% to 72% over the past 6 months but you can't pinpoint why. Production is slower, quality issues are increasing, and unexpected failures are becoming more frequent. You suspect several motors and drives are degrading but you don't have baseline performance data to prove it. Meanwhile, your plant is bleeding efficiency—reduced throughput costs $12K daily but you can't justify capital replacements without hard data.
Real-Time Equipment Health Monitoring
Get instant visibility into equipment condition across your plant with real-time monitoring of vibration, temperature, pressure, and performance metrics that predict failures before they happen.
Navigate Assets by System Hierarchy
Browse your plant equipment using industry-standard Uniformat classification. Drill down from building systems to individual assets, find related equipment instantly, and understand how assets connect across your facility.
Comprehensive Plant Operations Solutions
Everything plant operators need to maximize uptime, prevent failures, ensure safety, and optimize production efficiency with data-driven maintenance strategies.
Complete Equipment Registry
Maintain a comprehensive registry of all plant equipment with specifications, installation dates, warranty info, and maintenance history.
Preventive Maintenance Scheduling
Schedule recurring maintenance based on time intervals, operating hours, or meter readings. Automatically generate work orders before equipment reaches service thresholds.
Performance Analytics
Track uptime, reliability, efficiency, throughput, and failure rates. Analyze performance trends to identify deterioration patterns.
Predictive Maintenance
Predict and prevent unscheduled downtime using performance data, failure history, and predictive models. Reduce downtime by 30-40%.
Safety Compliance
Monitor safety systems, document Lock-Out Tag-Out procedures, track inspections, and ensure OSHA compliance with automated calendars.
Critical Equipment Prioritization
Prioritize maintenance based on equipment criticality, operational impact, and production requirements with risk-based scoring.
Production Work Orders
Streamlined work order management for production environments with shift handoffs. Schedule maintenance during planned downtime.
Reliability Metrics
Track MTBF, MTTR, and OEE. Benchmark reliability, identify chronic failure modes, and measure maintenance effectiveness.
Spare Parts Integration
Integrate maintenance with spare parts inventory to ensure critical parts availability. Track consumption and set reorder points.
Optimize Your Plant Operations
Reduce unscheduled downtime by 30-40%, improve equipment reliability, and ensure safety compliance with predictive maintenance.