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MANUFACTURING
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Downtime is a production number, not a maintenance one.

Preventive maintenance schedules, breakdown response, spare parts and maintenance cost — connected to the downtime recorded on the shop floor rather than logged separately.

The problem

Maintenance and production usually keep separate downtime records that never agree. Production counts hours lost; maintenance counts jobs done; neither can say what a machine's unreliability costs per month.

When the breakdown recorded by the operator opens the maintenance job, the two records are one — and preventive schedules can be justified against the downtime they avoid.

Core workflow

Asset to avoided downtime.

01
Asset register
Machines, lines and critical spares identified.
02
PM schedule
By calendar, running hours or output count.
03
Breakdown
Operator downtime entry opens a maintenance job.
04
Execution
Technician, hours, spares consumed and cause.
05
Cost
Labour and parts costed to the asset and line.
06
Reliability
MTBF, MTTR and downtime cost per asset.
What it covers

Preventive

PM schedules and checklistsCalendar and usage triggersTask assignment and calendarCompliance and overdue PMStatutory inspections

Corrective

Breakdown notificationJob assignment and priorityFault and cause codingRepair history per assetEscalation on critical assets

Spares & cost

Spare parts inventoryCritical spare min levelsMaintenance labour hoursCost per asset and lineMTBF and MTTR
Operational outcomes
−41%
Unplanned downtime hours
94%
Preventive maintenance compliance
1
Downtime record, not two
−26%
Critical spare stock-outs

Ranges observed on Al Jawad engagements. Targets agreed in assessment.

Cost the downtime on one line.

We reconcile production and maintenance downtime records for one line and put a cost on unreliability.