Our customer is a major Indian steel manufacturing company operating multiple production plants across the country. They use SAP PM to manage their assets and maintenance operations across complex steel production environments.

Business Scenario

A key priority was to increase wrench time and reduce downtime by digitizing and optimizing their inspection and maintenance planning processes to improve operational efficiency and asset reliability.

Challenges

Operating with paper-based processes and scattered information, the steel manufacturer struggled with limited technician access to critical data, maintenance inefficiencies, and high equipment downtime.

• Scattered and Inaccessible Information – Technicians lacked real-time access to technical specifications, equipment history, and permit data, resulting in compromised safety standards and maintenance quality.
• Paper-Based Processes – Manual data entry created incomplete and error-prone records, slowing resolution tracking, increasing maintenance backlogs, and hindering continuous improvement efforts.
• High Downtime Due to Inefficiencies – With limited digital tools for planning, tracking, and communication, maintenance teams struggled with delays, suboptimal task scheduling, and extended equipment outages.

Solution

Built using Procify, our AI-powered low-code/no-code platform.

The customer selected Procify Maintenance Planning Board and Procify Mobile Asset Maintenance to address these issues. Both solutions were chosen for their intuitive UI, enterprise-grade security, and scalability, deployed on a SaaS model with BYOD approach.

• Equipment Master Access – Provided technicians with real-time mobile access to complete asset history, Bill of Materials (BOM), measurement readings, and technical documentation, enhancing decision-making capabilities on the production floor.
• Work Order and Notification Management – Enabled field teams to create, view, and close work orders directly on mobile devices, with integrated failure logging, resolution tracking, and workflow automation.
• Permit Integration – Implemented contextual display of permit information and safety requirements directly within work orders, ensuring better safety compliance and reducing safety incidents during maintenance operations.
• Full SAP Integration – Configured seamless synchronization ensuring all field data flows automatically into SAP PM, maintaining consistency across workflows and eliminating duplicate data entry.
• Digital Attachments Capability – Enabled attachment of Standard Operating Procedures (SOPs) and GPS-tagged photos to work orders for better documentation, knowledge capture, and audit readiness.
• Cross-Platform Accessibility – Deployed “model once, use anywhere” solution accessible across Android and iOS devices in both online and offline modes, supporting diverse field conditions.

Business Impact

• Increased Wrench Time by Over 20% – Digital tools and mobile access reduced administrative burden, allowing technicians to spend more time on actual maintenance work.
• Eliminated Paper-Based Work Order Tracking – Complete digitization of work orders eliminated manual paperwork, data entry errors, and administrative overhead.
• Reduced Downtime – Faster task completion through real-time information access and streamlined workflows minimized equipment outages and production losses.
• Improved First-Pass Quality – Real-time issue capture and complete asset information enabled technicians to resolve problems correctly on the first attempt.
• Enhanced Safety with Integrated Permit Visibility – Contextual permit information and safety data reduced safety incidents and improved compliance with regulatory requirements.

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