About the Customer
The customer, a leading oil and gas organization based in Eastern India, operates multiple plants and uses SAP PM to manage its vast network of assets across complex refining and processing operations.
Business Scenario
As their capacity scales from 3 MMT to 9 MMT, they aimed to go paperless in inspection and servicing processes. Their goal was to increase technician efficiency, eliminate data entry errors, and enable proactive and timely response mechanisms.
Challenges
Operating with paper-based maintenance processes, the oil and gas company struggled with low wrench time, incomplete records, safety concerns, and growing maintenance backlogs.
- Low Wrench Time and Workforce Inefficiency – Technicians spent excessive time on paperwork and searching for information instead of performing actual maintenance work.
- Unavailability of Relevant Information On-Site – Lack of equipment specifications, history, and measurement trends on mobile devices reduced work quality and decision-making capability.
- High Error Rate in Paper-Based Data Entry – Manual data entry created incomplete and untrustworthy maintenance records in SAP, undermining asset management reliability.
- Difficulty Executing Planned Inspections – Lack of governance and digital tracking made it challenging to execute planned inspections and calibrations consistently.
- Growing Maintenance Backlog – No instant tracking or alerts led to accumulating maintenance tasks and delayed responses to critical issues.
- Limited Access to Permit Data – Insufficient permit information availability on-site led to safety incidents and compliance violations in hazardous environments.
- Downtime and Delays in Closing Notifications – Paper-based workflows caused significant delays in notification closure and extended equipment downtime.
Solution
Built using Procify, our AI-powered low-code/no-code platform.
The customer implemented Procify Mobile Asset Maintenance as part of a comprehensive digital transformation effort, deployed on SaaS-based cloud with BYOD policy across Android and iOS platforms.
- Equipment Master Access – Provided controlled access to equipment data, historical records, measurement readings, and Bill of Materials (BOM) details for comprehensive technician support on mobile devices.
- Work Order and Notification Management – Enabled technicians to create, view, edit, and complete work orders and notifications on mobile, with real-time failure and resolution tracking capabilities.
- Permit Integration – Made contextual permit details accessible directly within work orders to improve safety compliance and reduce incidents in high-risk operations.
- Spare Parts Management – Allowed technicians to issue spare parts and tools, and log consumption directly against work orders, improving inventory control and cost tracking.
- Full SAP Integration – Ensured all data captured in the field was automatically synced with SAP PM, maintaining seamless and updated workflows, reporting, and asset records.
- Digital Attachments – Enabled support for multiple attachment types, including Standard Operating Procedures (SOPs) and GPS-tagged, time-stamped asset photos for documentation.
- Mobile Reports – Provided technicians with ability to monitor daily and monthly reports on assigned and completed tasks, improving accountability and performance tracking.
Business Impact
- Over 50% Increase in Wrench Time – Digital tools eliminated paperwork and improved information access, allowing technicians to focus on actual maintenance work.
- Eliminated Printed Work Orders – Complete digitization of inspections and work orders removed the need for paper-based processes and manual logging.
- Reduced Equipment Downtime Significantly – Faster response to issues and improved maintenance accuracy minimized unplanned equipment outages.
- Real-Time Visibility – Enabled instant visibility into job status, asset condition, and material usage across all maintenance operations.
- Enhanced Operational Safety – Integrated access to permit data improved safety compliance and reduced incidents in hazardous environments.
- Improved Maintenance Accuracy – Capturing resolution details at the point of service enhanced work quality and first-time fix rates.
- Strengthened Spare Parts Control – Usage tracking linked to work orders improved inventory management and reduced excess stock.
- Streamlined On-Site Workflows – Image capture, GPS tagging, and barcode tools optimized field operations and documentation.
