Enterprise platforms · Manufacturing
CMMS and maintenance management software
We build custom CMMS and maintenance management software for manufacturers and process industries: an asset register, preventive and condition-based maintenance, work orders from request to closure, spare parts and MRO inventory, and a mobile app for technicians. Machine hours, counters and alarms can raise work automatically, and you own the code.
Requirements template · Manufacturing
Manufacturing systems requirements template
A requirements template for a manufacturing execution system or manufacturing operations layer, organised around ISA-95: orders, scheduling, shop-floor data, traceability, quality, equipment and integration.- 01Eight requirement areas written as testable statements.
- 02The fields a machine signal list needs before you connect equipment.
- 03Integration points with the ERP and the plant network.
- 04Seven questions to put to any vendor or development partner.
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What the system does, module by module.
- 01
Asset register
A hierarchy of sites, lines, machines and components with specifications, documents, warranties and criticality ratings. - 02
Preventive maintenance
Calendar and meter-based plans with task lists, estimated time and required parts, generating work orders automatically. - 03
Condition-based triggers
Work raised from machine hours, cycle counts, vibration, temperature or alarms received from the MES, SCADA or sensors. - 04
Work request and approval
Requests from operators with photos and location, triaged by a planner, prioritised by criticality and approved by cost. - 05
Planning and scheduling
Work orders planned against technician skills, shutdown windows and parts availability, with a schedule that supervisors can adjust. - 06
Technician mobile app
Assigned jobs, checklists, readings, photos, time and parts used, captured offline at the machine and synchronised afterwards. - 07
Spare parts and MRO inventory
Stores, bins, reorder points, reservations against work orders and linking of parts to the machines that use them. - 08
Failure analysis and reliability
Failure codes, causes and remedies captured on each job, with MTBF, MTTR and Pareto analysis to find repeat failures. - 09
Contractors, safety and cost
Contractor jobs and invoices, isolation and permit links for hazardous work, and maintenance cost by asset, line and period.
Reference architecture.
Standards and interfaces
What we design against.
- ISO 55000
- Asset management system standard, for policy, objectives, risk and performance evaluation.
- ISO 14224 and EN 13306
- Equipment taxonomy and failure data collection, and maintenance terminology, used to keep codes consistent.
- Reliability-centred maintenance
- SAE JA1011 criteria for an RCM process, used to define which tasks and intervals are worth doing.
- ISO 22400
- Maintenance and equipment key performance indicators used in the reports.
- OPC UA and MQTT
- Sources of machine counters, states and alarms that trigger maintenance work.
- OWASP MASVS
- Security verification for the technician mobile app.
Data model
The core entities.
- Asset
- Hierarchy position, specification, criticality, installation date, documents and warranty.
- Maintenance plan and task
- Trigger (calendar or meter), task list, estimated duration, skills and parts.
- Work order
- Request, priority, plan, assignee, time, parts used, readings and closure notes.
- Meter and condition reading
- Value, unit, time and the source machine or sensor.
- Failure record
- Failure mode, cause, remedy, downtime and the asset affected.
- Spare part and stock
- Part, location, quantity, reorder level, reservations and supplier.
- Contractor job
- Scope, contractor, permit, invoice and approval.
When custom development is the right call.
Controls designed in, not added later.
Role-based access
Requesters, planners, technicians, stores and contractors have distinct roles and views.Approval of cost and risk
Work above cost or risk thresholds needs approval, and safety-critical work links to permits and isolations.Resilience on site
The technician app works offline and the system keeps recording during outages.Integration integrity
Triggers from machines are de-duplicated and rate-limited so an alarm storm does not create hundreds of jobs.Audit trail
Changes to plans, assets and work orders carry user and time.
From discovery to a system you run.
- 01
Maintenance process review
We follow work from request to closure with maintenance, production and stores, and record the codes, forms and spreadsheets in use. - 02
Asset and plan design
The asset hierarchy, criticality, failure codes and plan templates are agreed, with machine triggers specified. - 03
Build and migrate one area
One area's assets and plans are loaded and used, with the technician app on the floor. - 04
Add triggers and stores
Condition-based triggers, spare parts and the link to production planning are added. - 05
Roll out and analyse
More areas follow, and reliability reports guide changes to plans.
Relevant work
Where to see our work.
Common questions.
- Can machines trigger maintenance work automatically?
- Yes. Hours, cycle counts, alarms or sensor readings received from the MES, SCADA or gateways can raise a work request or order according to rules, with de-duplication so one fault creates one job.
- Does the technician app work without a connection?
- Yes. Jobs, checklists, readings and photos are available offline and synchronise when the connection returns.
- How do you find repeat failures?
- Every job records failure mode, cause and remedy against the asset, and reports show the most frequent and most costly failures with MTBF and MTTR.
- Does it connect to purchasing and stores?
- Yes. Parts reserved on a work order trigger replenishment, and purchase orders and receipts flow with the ERP.
- Who owns the code?
- You do. The code, the plans and the data stay yours.