44% Less Downtime.
16% Higher OEE.
How a Multinational FMCG Manufacturer Stabilized Operations with Predictive TPM—without replacing legacy control systems.
01 // THE CHALLENGE
When Every Minute Costs Money
In high-speed FMCG environments, efficiency margins are razor-thin. This facility operated multiple packaging lines where reactive maintenance was bleeding revenue.
Reactive Culture
Equipment degradation went unnoticed until sudden failures occurred, forcing emergency line stoppages.
Fragmented Data
Work orders and spare parts history were scattered across manual logs, limiting accountability.
The OEE Blind Spot
OEE was calculated retrospectively, masking real capacity losses and preventing proactive optimization.
02 // THE SOLUTION
A Predictive TPM Command Center
Niotek deployed the HORUS TPM Module as a non-invasive operational intelligence layer.
Unified Maintenance Command
A centralized command center was established to track MTTR, MTBF, and task completion in real time. Maintenance teams now operate from a single source of truth.
Predictive Anomaly Detection
Equipment health is continuously monitored for wear. Maintenance teams receive early warnings, allowing interventions to be planned instead of rushed.
Automated TPM Workflows
Work orders are now triggered, assigned, and tracked systematically—eliminating manual errors and missed interventions.
03 // THE RESULTS
From Chaos to Control
Within four months, the facility transitioned to a structured, predictive model.
| Metric | Before HORUS | After HORUS | Impact |
|---|---|---|---|
| Unplanned Downtime | ~52 hrs / mo | ~29 hrs / mo | 44% Reduction |
| OEE Score | 62% | 78% | +16% Gain |
| MTTR | 2.4 hrs | 1.3 hrs | 46% Faster |
| Schedule Accuracy | ~40% | 90%+ | 2.25x Improvement |
TECHNICAL SPOTLIGHT
Zero Rewiring Integration
Connected directly to existing PLCs on packaging and filling lines without modifying core control logic.
Root Cause Analysis
Structured fault classification enabled faster diagnosis and repeat-failure elimination.
Cost Avoidance
Achieved 18–22% annual maintenance cost avoidance by extending asset life and eliminating emergency repairs.
"Predictive maintenance isn't just about saving machines. It's about saving time."
This project proved that TPM excellence in FMCG does not require new machines or disruptive upgrades. By digitizing maintenance workflows, the manufacturer achieved a significant increase in OEE and reliability.