Digital Transformation of Maintenance Management in the Mechanical Shop

Objectives and Challenges

This project focused on modernizing the maintenance system of the mechanical shop, aiming for digital transformation and process improvement. The main goals were:

Develop a solution that added value to the team’s daily routine
Ensure the team had an effective tool with intuitive navigation and minimal screen time

Client Pain Points

The main challenge was adapting the traditional shop floor workflow to a digital format while minimizing disruption:

Lack of an efficient tool to manage the team’s daily inspections
Manual processes and information stored individually by team members in personal notes, limiting quick access to necessary data
High volume of physical inspection records

Solution and Results

To address these challenges, we implemented the following solutions:

Conducted a Gap Assessment to map current needs and process gaps
Created an inventory of 224 repairable assets and structured the master data in Plex, including bill of materials, drawings, and diagrams—ensuring quick access to all relevant information
Developed a mobile-compatible Plex tool for daily inspections, streamlining the process and increasing efficiency
Implemented QR Codes so all relevant information was easily accessible in a centralized location for shop operations
Enabled remote access, allowing updates to be made directly at the equipment or workstation without the need to return to the office
Facilitated access to asset history for more accurate and faster control
Created a workflow for the internal equipment repair process, optimizing management
Integrated data with Power BI for consolidated dashboards tracking work orders, repair status, and purchase requests, using a clean, user-friendly interface
Enabled management of equipment sent for external repair through Plex integration

Roadblocks

Usability of Plex Systems: Ensuring all users could efficiently and intuitively use the platform

Benefits

Financial: Improved budget control enabled by easy access to data, supporting more informed decisions and reducing operational costs

People: Better use of team time with fast and accurate access to information, eliminating reliance on manual records or physical files

Availability: Increased equipment availability through faster repairs and reduced downtime

Time: Significant reduction in time spent searching for and updating information, making processes more efficient

Integration: Improved integration between internal and external operations, providing a unified view of maintenance data and processes