Transforming Maintenance at India’s Leading Paint Producer by leveraging Industry 4.0

Transforming Maintenance at India’s Leading Paint Producer by leveraging Industry 4.0

Customer Profile

A prominent global paint company is renowned for its innovation, quality, and customer-centric approach. Established in 1942, it has grown to become the largest paint manufacturer in its country and one of the top ten paint companies worldwide. This company offers a diverse range of products, including interior and exterior wall paints, enamels, wood finishes, and industrial coatings. With a strong focus on sustainability and technology, it continues to enhance customer experiences and drive industry standards.

Challenges Encountered 

  • Required deployment of a uniform CMMS solution that could be integratedwith DCS, other OT applications and SAP to ensure standardization and seamless operations across all manufacturing facilities.
  • Need to Streamline the Maintenance Process:
    • Digitalize all Asset Information
    • Effective and Online Data Capture
    • Productivity Improvement
  • Necessity to effectively manage their outsourced maintenance workforce
  • Transition towards Condition-based Maintenance 
  • Requires the implementation of Reliability-Centred Maintenance to enhance Asset Care practices.
  • Analytics solution to monitor equipment history and ensure regulatory compliance effectively.

Strategic Solutions by MaintWiz 

  • MaintWiz has been implemented across multiple manufacturing plants in India and several international units
  • The flexible & comprehensive asset hierarchy perfectly mirrored multi-plant complex setup 
  • Equipment, Sub-assemblies, Instruments, Spares
  • Condition Monitoring functionality to gather condition data, with prospective
  • MaintWiz has been established to oversee Operations & Maintenance Contractors, featuring:
  • A mobile application for contractors to enter Work Order (WO) data
  • A system for  officers to provide approvals
  • Complete Maintenance Function
  • Preventive Maintenance Scheduling & Execution
  • Breakdown tracking & Metrics monitoring
  • Spares Management (Integration to SAP)
  • Instruments & Calibration Schedules
  • Condition Parameter Monitoring (Integration to DCS)

Transformative Benefits of MaintWiz

  • Streamlined the entire maintenance function into one single application. Central monitoring by Subject Matter Experts – of all Plant Engineering activities
  • The Mobile app functionality revolutionized O&M contractor monitoring, allowing for efficient work order data entry by contractors and swift approvals by  officers, leading to a 95% reduction in approval time, greatly improving efficiency and accountability. 
  • Vendor management for AMC work – Alerts to Vendors
  • MaintWiz serves as Knowledge Repository of critical information, including equipment history, standard operating procedures (SOPs), task lists, documents, and details related to spares and services usage.
  • Shifted from Preventive to predictive maintenance by condition monitoring and robust integration with plant systems
  • Substantial operational improvements, including Cost Optimization, Lower Mean Time to Repair (MTTR), Increased Uptime, and Improvement in Compliance
  • Productivity Improvement due to 1. Ease of use and 2. Workflows & Approvals
  • The reporting capabilities of MaintWiz provides data-driven actionable insights, intuitive graphs and executive dashboards.
Want to see MaintWiz in action?

Request a one-one demo with our solution engineering team.

Want to see MaintWiz in action?

Request a one-one demo with our solution engineering team.