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