We built a state-of-the-art Computerized Maintenance Management System (CMMS) to streamline maintenance across individual plants or groups of plants. It serves as the daily maintenance backbone for over 2,500 users, replacing manual logbooks and disconnected spreadsheets with automated scheduling, QR-code-driven asset lookups, and closed-loop mobile-to-web workflows.
Technology Stack
The Challenge
Industrial maintenance teams need to track a large, hierarchical asset base (plants, sections, equipment, sub-equipment, parts), keep preventive maintenance on schedule, and respond quickly when something breaks - all while keeping engineers in the field connected to the office in real time. Paper-based or spreadsheet-driven processes made this hard to scale and impossible to audit.
Key Features We Built
- Hierarchical asset registration and management across plants, sections, equipment, and parts
- Preventive maintenance scheduling with automated yearly, monthly, and daily calendars
- Breakdown maintenance management that auto-generates work orders from logged incidents
- QR code integration for instant access to equipment details and maintenance history
- A mobile app for maintenance engineers to view tasks, update work orders, and attach media
- Measuring points with trigger-based work order creation when readings cross set thresholds
- Automated real-time dashboards across work orders, equipment status, and triggers
How It Works
Companies register their full asset hierarchy once, then upload maintenance schedules per equipment type; the system automatically builds yearly, monthly, and daily calendars and pushes daily task lists to engineers' mobile app. If equipment breaks down, logging an incident automatically generates a work order and notifies the right department instantly. Every piece of equipment carries a QR code - scanning it instantly surfaces its history, open work orders, and associated tasks for fast decision-making.
Engineers close the loop from the field: they update work orders, attach photos, videos, or voice notes as evidence of completed work, and supervisors review and close orders from the web portal. Measuring points let teams record readings via mobile or web, with triggers that automatically raise a work order once a defined condition is met.
The Outcome
The CMMS now generates over 3,000 work orders and captures more than 40,000 measurements every day, serving 2,500+ active users. By combining hierarchical asset management, QR-code lookups, and trigger-based automation in one closed-loop mobile-and-web system, plants using it have cut downtime and replaced manual maintenance tracking with real-time, auditable operations.