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Energy industrial · international group · maintenance

Machine stoppages reported, escalated and visible on the site map.

A maintenance team in an international energy group replaces a slow alert flow and hand-kept tracking with an application built outside central IT.

÷2maintenance intervention time, according to the team's estimate
4 levelsof automatic escalation, from 0 to 60 minutes, until someone takes the alert
V2ordered by the client after the prototype, now live
The flow
  1. ReportingProduction reports the stoppage: area, equipment, severity, photo.
  2. EscalationEmail and text by area, then 15, 30 and 60 min without anyone taking it.
  3. InterventionTaken, on site, resolved: every state is time-stamped.
  4. Digital twinThe equipment turns green, orange or red on the site map.
  5. IndicatorsTime to acknowledge and to repair, calculated automatically.
The path of one alert, from the shop floor to the office.

The context

On site, production reported a stoppage through software that could take several minutes to load on a tablet, while a shared spreadsheet was kept in parallel and consolidated by hand. Maintenance indicators were hard to calculate, and the group's central maintenance tool could not adapt to the site's needs.

What was built

  • Reporting: a form for production (severity, area, equipment, description, photo), and tracking in four states: new, taken, on site, resolved.
  • Escalation: email and text to the right people by area, then to the next levels if nobody takes the alert in time.
  • The digital twin: the site map with each piece of equipment in green, orange or red in real time, the indicators (mean time to acknowledge and to repair, critical stoppages, equipment at risk) and the history per machine.
  • The V2: preventive maintenance with routines by frequency, work orders, risk checklists, role-based accounts, designed phone-first.
Site map · live statusFictional example
Area A · assembly
Press 01
Conveyor 02
Robot 03
Area B · machining
CNC lathe 04
Milling 05
Area C · testing
Bench 06
Bench 07
Compressor 08

Open alert · CNC lathe 04

0 minArea technician
15 minTeam leader
30 minMaintenance manager
60 minSite management
Fictional data. Escalation stops as soon as a technician takes the alert.

How

An on-site audit to listen to maintenance and production, then a complete prototype built in a few days and shown to the site manager. A presentation to the management committee, then a V2 ordered and delivered in stages, with team training. Everything runs without depending on central IT.

What changed

Stoppages are reported and tracked in one place, and maintenance indicators are calculated without manual consolidation. According to the team's estimate, maintenance intervention time is halved. The team has its accounts and training, and preventive routines are live. The client plans to roll the tool out to other sites, each with its own database.

Further reading