solutions / preventive maintenance & spares
Plant · IIoT · BASF
Maintenance that happens before the breakdown does.
Preventive maintenance, spares and equipment manuals for BASF's line - planned on the equipment tree, tracked down to the part.
Where this started
The same plant that calls for help when something breaks also needs the discipline that keeps things from breaking. BASF's maintenance ran on memory and spreadsheets - which spare goes into which assembly, when it was last changed, where the manual is. The fix was to put the whole maintenance world on the same equipment tree the andon system already used.
Decision 01
Schedules live on the equipment tree, down to the part.
A PM entry is not a calendar note - it binds equipment, sub-equipment, assembly and the exact BOM spare part with quantity, a frequency in months, and schedule and follow-up dates. The status of the spare itself - available, requested, issued, consumed - travels with the task.
Decision 02
The storeroom keeps score.
Every spare movement is a signed register entry: inward and outward with issued-by, received-by and inwarded-by, against article number, make, model and rack location - with a live available count per article. Requests flow through the same module, so stock and demand meet in one place.
Decision 03
The manual is attached to the machine, not a shelf.
Service documents are mapped to the exact equipment, sub-equipment and assembly they describe. Whoever picks up the job opens the right procedure from the record - no hunting through folders.
The result
BASF's maintenance now runs on schedule instead of memory. Every PM task knows its part and its dates, every spare movement carries a name, and every machine carries its own documentation - the unglamorous discipline that keeps an assembly line out of the breakdown queue.
Planned to the part
PM schedules bound to equipment, assembly and BOM spare with quantity, monthly frequency and follow-up dates.
Every spare accounted for
Signed inward/outward register with live available counts by article, make, model and rack.
Knowledge where the work is
Manuals mapped to the exact equipment, sub-equipment and assembly they describe.
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