01 · The problem
What problem does it solve?
A plastics and machining plant has 120 machines and utilities, and a maintenance team of nine. Preventive maintenance is a wall chart; breakdowns are reported by shouting across the floor or calling the supervisor.
A compressor missed two monthly services and failed during a rush order. Nobody can say which machines break down most, or whether the same fault keeps coming back.
Unplanned downtime
Breakdowns that a service would have prevented.
Repeat faults
The same failure, fixed the same way, again.
Spares surprises
Critical parts out of stock when needed.
No history
A machine’s record is in someone’s head.