Line 2 · 09:12 · unplanned stop

A machine stops.
The clock starts.
Who knows?

Right now that answer is a phone call, a WhatsApp group and a register nobody has updated since March. Play through what the same hour looks like on Fast Maintenance.

CNC-04 · Machining Line 2 Down
Downtime running
00:42:17
Production lost so far
₹2,952
₹4,200
per hour
Fault
Spindle noise
Reported by
Operator
Assigned
None

Simulated plant data — everything here is live and clickable

01 — The real number

Downtime is not an engineering problem. It is a bill.

Most plants never total it up, because the hours are scattered across shifts and registers. Move the sliders to your plant and see the year.

Unplanned downtime, this year
₹60 lakh
750 production hours lost across the plant
Back in your pocket at that reduction
₹18 lakh
That is the size of the problem Fast Maintenance is pointed at.
Failure 01

Nothing warned you

The bearing had been noisy for a week. Nobody logged it, so nobody scheduled it, so it failed mid-shift.

Failure 02

Nobody knows what is due

The PM plan lives in one person's diary. When he is on leave, the month's servicing quietly does not happen.

Failure 03

The spare is not on the shelf

The belt is a ₹900 part. Sourcing it takes three days. The machine sits idle for all three.

02 — Every asset carries its own file

Tap the tag. The machine tells you everything.

Every machine, tool, gauge and utility is registered once and gets a printed barcode / QR tag or an NFC sticker. A technician scans it on his phone and the whole asset file opens — specs, spares, warranty, history. No hunting for a folder.

Asset tag — CNC-04 Printed label, Line 2
AssetCNC-04
MakeHaas VF-2
SerialVF-2-8891
PlantMachining Line 2
Tap to scan

What the register holds

  • Asset code, specifications, make / model / serial
  • Photographs of the machine and its sub-assemblies
  • Location allocation, plant and line
  • Barcode / QR printing, bulk Excel import and export

What hangs off it

  • Spare part list (BoM) linked to the parent machine
  • Re-order levels on every spare
  • AMC and warranty expiry alerts
  • Full maintenance and transaction history

Who uses it that way

  • Technician on the floor, on a phone, one-handed
  • Store keeper issuing the right part first time
  • Auditor asking for one machine's complete record
  • Planner deciding what to service this week

Waiting for a scan
Point the camera at the asset tag

03 — The hour that costs you money

One breakdown, start to close. Watch the clock.

This is the real sequence: reported from the floor, alerted on WhatsApp, assigned, diagnosed, spare issued from the store, permit signed, repaired, closed. Every step timestamped, every minute counted.

BD/26-27/0231·CNC-04·Spindle noise Not started
Downtime
00:00
Cost so far
₹0
Plant MTTR
3.4 h
Availability
94%
04 — The point of all this

Fixing fast is good. Not breaking is better.

Preventive schedules run by calendar or by running hours. Each one raises a due alert, auto-creates the work order, carries its checklist and safety work permit, and sets the next due date when it closes. Same 30 days, two different months.

Line 2 — 30 days on registers and memory
Breakdown Preventive done Calibration recall Running
Unplanned stops
7
Downtime hours
61
PM completed
0 of 6
Availability
91%

Preventive & planned

  • Schedules by calendar date or running hours
  • Assign users and spares to each schedule
  • Due alerts, maintenance calendar, follow-up dashboard
  • Auto-reschedules the next due date on close

Checklists & work permits

  • Machine-wise and maintenance-type-wise checklists
  • Safety regulation checklist and work permit master
  • Each check recorded OK or not-OK, with photographs
  • A not-OK check raises a corrective job on the spot

Calibration & gauges

  • Gauge register with calibration frequency
  • Calibration-due recalls on the same due list
  • Certificates stored against the gauge
  • Ready for IATF and ISO 9001 audits
05 — The control tower

What is down right now — without walking the floor.

A live status board for every asset, and the reliability numbers that tell you whether maintenance is actually improving. MTTR, MTBF, availability, downtime by cause, PM compliance, spare consumption.

MTTR
3.2 h ↓ 22%
MTBF
412 h ↑ 31%
Availability
96% ↑ 5 pts
PM compliance
94% ↑ 40 pts

Boards you run the shift on

  • Live machine status
  • Breakdown ageing by technician and priority
  • PM-due and calibration-due this week
  • Maintenance calendar

Numbers you report upward

  • MTTR and MTBF per machine, over time
  • Downtime by asset, line, cause and period
  • Breakdown frequency and repeat failures
  • Spare consumption, stock value and re-order status

Records the auditor asks for

  • Complete asset history report
  • Every PM, breakdown, spare and cost per machine
  • Signed work permits and completed checklists
  • Ready for TPM review, ISO 55000 and IATF
06 — Dhruv AI

Ask the plant a question in plain English.

Dhruv AI reads your asset history and answers. It also clusters free-text breakdown remarks into recurring failure themes — the patterns a fixed report will never show you. Pick a question.

DDhruv AIRead-only — your data stays in your database
Which machine cost me the most downtime last month?

Stop running maintenance on registers and WhatsApp groups

See how Fast Maintenance handles your exact assets, PM schedules and breakdowns. Live demo, your machines, your spares, your questions. No generic slideshow.

Get a free demo View pricing
No setup fees On-premise or cloud Standalone or with the Fast Suite 3 months onboarding support