Power Generation
Coal Plant Cuts Unplanned Downtime by 40%
A 450MW coal-fired plant was running purely reactive maintenance. Turbine trips were costing $50K per event, and the maintenance backlog had grown to 800+ open work orders.
OptimaintAsset built a complete asset hierarchy from scratch, implemented time-based and condition-based PM schedules, and deployed mobile work orders to field technicians.
Results after 12 months:
Unplanned downtime down 40%. Maintenance backlog cleared in 6 months. First-year cost avoidance of $2.3M. PM compliance reached 91%.
Heavy Manufacturing
200-Machine Facility Ditches Excel for CMMS
A metal fabrication plant with 200+ machines was running on spreadsheets and whiteboards. No work order history, duplicate PMs, and parts stockouts were shutting down production lines weekly.
We migrated 15 years of partial records, built BOMs for 60 critical assets, and set up automated PM scheduling with parts reservation.
Results after 8 months:
Emergency work orders down 60%. PM compliance up to 94%. Parts stockouts cut by 70%. Maintenance planners now spend time planning, not chasing paper.
Mining
Mining Fleet Tracked Across Three Remote Sites
An open-pit mining operation with 80 haul trucks and loaders across three remote sites had no centralized maintenance tracking. Mechanics used paper logbooks, and fleet availability was guessed, not measured.
OptimaintAsset deployed mobile work orders for field mechanics, linked GPS locations to asset records, and added fuel and tire life tracking dashboards.
Results after 10 months:
Fleet availability up 12%. Tire life extended 18% through better pressure and haul tracking. Maintenance cost per operating hour down 15%.
Chemical Processing
Chemical Plant Passes FDA Inspection with Zero Findings
An FDA-regulated chemical facility had no maintenance documentation trail. Calibration records were expired, audit prep took three weeks, and the risk of a 483 observation was growing.
OptimaintAsset implemented calibration scheduling, attached calibration certificates to every asset record, and built an automatic audit trail for every work order.
Results after 6 months:
FDA inspection passed with zero findings. Calibration compliance at 99.7%. Audit prep time reduced from 3 weeks to 2 days.