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Sample Manufacturing Kft. Mixed packaging & CNC · 25 assets

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Overview

Key metrics

Assets
25
Critical
4
Downtime YTD
612 h
Annual opportunity
€218,400
MTBF
214 h
Reactive WOs
62%
Action Center

Top recommended actions

AI-ranked by business impact and payback

Machine_A_01 · Packaging Line 1
Move Packaging Line 1 vacuum system to Condition-Based Maintenance

Vacuum pump failures account for 41% of Line 1 downtime. Vibration + vacuum-pressure monitoring catches degradation 3-5 weeks early.

+€96,000/yr48% downtime4 mo paybackCondition-Based
Machine_C_01 · Air Compressor #3
Deploy vibration monitoring on Air Compressor #3

Threshold exceeded 4× in 90 days. A single unplanned failure costs ~€18k in packaging line stop.

+€52,000/yr62% downtime3 mo paybackPredictive
Machine_A_05 · Vacuum Sealer A5
Standardize PM on seal replacement every 900 cycles

Seal wear is the dominant failure mode. Current run-to-failure produces MTBF of 118h; PM at 900 cycles pushes MTBF above 260h.

+€34,000/yr35% downtime2 mo paybackPreventive
Machine_B_02 · CNC Lathe #3
Add spindle bearing vibration route (weekly)

Two bearing-related stops in Q2. Route inspection prevents catastrophic spindle replacement (~€28k parts + 3-day stop).

+€22,000/yr40% downtime5 mo paybackCondition-Based
Machine_F_01 · Filling Station F1
Replace obsolete pressure sensor with drift-tolerant model

Sensor drift causes false rejects and unplanned stops. One-time capex; eliminates 12+ nuisance stops per year.

+€14,400/yr28% downtime6 mo paybackPreventive
Business Impact

Cost & opportunity

Annual avoidable downtime
612 h
Annual opportunity
€218,400
Average payback
4.0 months
Capex required
€48,000
Net year-one impact
€170,000
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Priority Ranking

Top priority assets

AssetCrit.MTBFAnnual cost
Packaging Line 1
Machine_A_01 · Packaging
592 h€96,000
Vacuum Sealer A5
Machine_A_05 · Packaging
5118 h€62,000
CNC Lathe #3
Machine_B_02 · Machining
4190 h€34,000
Air Compressor #3
Machine_C_01 · Utilities
5140 h€52,000
Assembly Robot D2
Machine_D_02 · Assembly
3320 h€12,000
Conveyor E1
Machine_E_01 · Logistics
2780 h€4,200
Filling Station F1
Machine_F_01 · Packaging
4210 h€22,000
Injection Molder G2
Machine_G_02 · Molding
3560 h€7,200
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Live math
Annual investment (capex)
€48,000
€10k€200k
Annual savings
€120,267
ROI
151%
Payback
5 mo
Downtime avoided
286 h
AI's recommended allocation at this capex: vibration monitoring on the top-3 critical assets, cycle-based PM on the vacuum sealer, drift-tolerant pressure sensor on the filling station. Reactive WO ratio would drop to ~45%.
Before / After

What changes with the platform

Before
  • Prioritization
    "Everything is critical"
  • Maintenance strategy
    62% reactive work orders
  • Executive report
    3 days of Excel + PPT
  • Financial impact
    Not quantified
  • Investment decisions
    Gut feel
  • MTBF (critical assets)
    92–140 h
After
  • Prioritization
    Top-5 ranked by business impact
  • Maintenance strategy
    CBM + cycle-based PM on top assets
  • Executive report
    1 minute, board-ready
  • Financial impact
    €218k annual opportunity surfaced
  • Investment decisions
    ROI + payback on every action
  • MTBF (critical assets)
    260+ h target with a plan

Click the After rows you want to focus on.

Asset Strategy

Recommended maintenance strategy

AssetRecommended strategyConfidenceAnnual savings
Packaging Line 1
Machine_A_01
Condition-BasedHigh€96,000
Air Compressor #3
Machine_C_01
PredictiveHigh€52,000
Vacuum Sealer A5
Machine_A_05
PreventiveHigh€34,000
CNC Lathe #3
Machine_B_02
Condition-BasedMedium€22,000
Filling Station F1
Machine_F_01
PreventiveMedium€14,400
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Executive Report

Board-ready summary

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