Per-machine service countdowns
Each machine has its own maintenance interval. The system counts down to the next service date and escalates as urgency increases.
Manufacturing
Preventive Maintenance System — Auto Components Plant
WALKTHROUGH · HYPOTHETICAL
15 STAFF USERS
AUTO COMPONENTS MANUFACTURER · 22 PRODUCTION MACHINES
7 WEEKS BUILD TIME
KEY OUTCOME
Unplanned downtime: 3 incidents/quarter → 0 in first 3 months
THE PROBLEM
What was happening before
The plant ran 22 CNC and production machines across two shifts. Maintenance was reactive — machines were serviced when they broke down, or when a technician felt 'something sounded off'. There was no documented schedule, no service history, and no way to know which machine was overdue.
In Q3, the same CNC machine broke down three separate times. Each time, a different technician responded. None of them knew what the previous technician had found. The third breakdown required a part replacement that could have been avoided if the wear had been caught during the first incident.
The operations head wanted a simple answer to one question: 'Which machine needs attention next?' There was no system that could answer it.
“I don't know a machine needs service until it stops working. Last quarter we lost 3 production days to the same CNC machine — the one that was 'always fine'.”
BEFORE
3/qtr
Unplanned machine breakdown incidents
3 days
Production days lost last quarter
22
Machines with no digital maintenance log
₹8L
Estimated quarterly downtime cost
THE SYSTEM
What I built
I built a preventive maintenance countdown for all 22 machines. Each machine has a defined service interval based on its operating hours and manufacturer recommendations. The system counts down from last service date and escalates colour-coded urgency as the date approaches.
Technicians log completed maintenance from a mobile interface — what was done, what was found, parts replaced. The system automatically resets the countdown from the new service date.
The operations head gets a single dashboard view: 22 machines, each showing days until next service, colour-coded from green to red. No Excel, no notebooks, no guessing.
Mobile service logging
Technicians log completed maintenance from any device — notes, parts replaced, next interval automatically reset.
Machine history timeline
Full service history per machine — maintenance done, by whom, and what was found.
THE OUTCOME
What changed
In the 3 months after go-live, zero unplanned breakdown incidents occurred. The system had flagged 14 upcoming services in that period — all 14 were completed on schedule.
The Q3 CNC machine that had broken down three times? Its service records now show the wear pattern that caused the recurring failures — caught and addressed in the first scheduled maintenance after go-live.
BEFORE3/quarter
improved to
AFTER0 in first 3 months
Unplanned breakdown incidents
BEFORE3 days/quarter
improved to
AFTER0
Production days lost to downtime
BEFORE0
improved to
AFTER22 (100%)
Machines with active service schedule
BEFOREUnknown
improved to
AFTERTracked per machine
Mean time between maintenance
Want a system like this for your manufacturing organisation?
Get a quote for Preventive Maintenance Countdown