44% Less Downtime. 16% Higher OEE.
How a global FMCG leader transformed its maintenance operations from reactive firefighting to a predictive TPM model, cutting downtime by nearly half and improving OEE—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 and filling lines where every minute of downtime directly translated into lost revenue. Despite strong demand, operations were constrained by reactive maintenance.
Reactive Maintenance Culture
Equipment degradation went unnoticed until sudden failures occurred, forcing emergency repairs.
Fragmented Data
Work orders and history scattered across manual logs, limiting accountability.
The OEE Blind Spot
OEE calculated retrospectively masked real capacity losses.
02 // THE SOLUTION
A Predictive TPM Command Center
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Unified Command
Centralized tracking of MTTR and MTBF. Maintenance teams now operate from a single shared source of truth.
Predictive Detection
Continuous monitoring of equipment health. Early warnings allow interventions to be planned instead of rushed.
Automated Workflows
Digitized preventive maintenance schedules. Work orders triggered and tracked systematically.
03 // THE RESULTS
Before vs. After HORUS
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| Metric | Before HORUS | After HORUS | Impact |
|---|---|---|---|
| Unplanned Downtime | ~52 hrs / month | ~29 hrs / month | 44% Reduction |
| OEE Score | 62% | 78% | +16% Gain |
| MTTR | 2.4 hrs | 1.3 hrs | 46% Faster Recovery |
| Schedule Accuracy | ~40% | 90%+ | 2.25× Improvement |
TECHNICAL SPOTLIGHT
Zero Rewiring Integration
Connected directly to existing PLCs on packaging and filling lines without modifying core control logic.
Root Cause Analysis (RCA)
Structured fault classification enabled faster diagnosis and repeat-failure elimination.
Cost Avoidance
Achieved 18–22% annual maintenance cost avoidance by extending asset life.
"Predictive maintenance is not just about protecting machines. It’s about saving time."
Achieve significant OEE increase and reliability through software and process intelligence alone.