Maintenance Planning & Asset Reliability System
Optimizing planned and unplanned maintenance through data-driven reliability insights across a production environment.
Duration
7 WEEKS
tEAM SIZE
5 ENGINEERS
INCIDENT REPORTING SPEED
OPERATIONAL COVERAGE
mULTI-LINE PRODUCTION FACILITY
PRODUCTION LINES, SUB ASSEMBLIES
The Challenge
Reactive Maintenance and Limited Asset Visibility
A large-scale production facility operating multiple lines and assemblies faced persistent challenges in managing both planned and unplanned maintenance activities. Maintenance events were logged manually or across disconnected systems, resulting in incomplete work-order history, limited insight into equipment reliability, and frequent unplanned downtime.
Maintenance planning was largely experience-driven rather than data-driven. Mean Time Between Failures (MTBF) and Mean Time Between Repairs (MTBR) were either unavailable or inconsistently calculated, making it difficult to proactively schedule maintenance or identify high-risk components within complex assemblies.
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“Without accurate failure data and structured work-order history, maintenance planning was reactive, leading to avoidable downtime and inefficient use of resources.”
Our Solution
Maintenance Planning & Reliability Intelligence Platform
We designed and delivered a comprehensive maintenance planning system tailored for production-floor environments. The solution combines a centralized maintenance management platform with a companion mobile application—Part Picker—to simplify maintenance logging directly at the source.
The platform establishes a single system of record for all maintenance activities, capturing detailed work-order history across production lines and assemblies. Reliability metrics such as MTBF and MTBR are automatically calculated for each component and sub-assembly, enabling maintenance teams to shift from reactive repairs to predictive, data-informed maintenance planning.
System Architect
Maintenance Planning Web Platform
Part Picker Mobile Application
Centralized Asset & BOM Databse
Reliability Analytics & Reporting Engine
Results and Impact
Implementing the Maintenance Planning System transformed maintenance operations from a reactive, experience-based process into a structured, data-driven discipline. By digitizing work-order logging and integrating reliability analytics, the organization gained clear visibility into asset performance across production lines and assemblies.
Maintenance teams were empowered with real-time access to component documentation and historical failure data, significantly reducing diagnosis time on the shop floor. The introduction of MTBF and MTBR metrics enabled proactive scheduling, reducing unplanned downtime and extending component lifecycle through timely intervention.
At an operational level, centralized maintenance intelligence improved coordination between engineering, production, and maintenance teams. The platform established a scalable foundation for predictive maintenance initiatives, improved equipment availability, and strengthened overall production reliability.
