Chemical Manufacturing Excellence with Cryotos CMMS

Challenges Faced

Before implementing Cryotos CMMS, the company faced multiple operational hurdles, including:

1. Inability to Track Complaints
   Lack of a systematic approach to capture and categorize complaints.
2. Difficult Meter Reading Capture
   Manual meter reading was difficult and time-consuming, which caused the acceptable limits (thresholds) to be set too wide. This often led to equipment failures happening more frequently because issues weren't detected early enough.
3. Unclear Breakdown Logging
   It was hard to track equipment breakdowns across different work shifts, and difficult to know which team was responsible or who had provided updates on an issue.
4. No Feedback Monitoring
   Difficulty in tracking and understanding feedback from teams working on-site, making it hard to know what issues they faced, how they felt about processes, and where improvements were needed.
5. Preventive Maintenance Neglected
   Preventive maintenance tasks were being done manually or not tracked properly, meaning scheduled upkeep and inspections were often missed or not recorded — leading to inefficiencies and potential equipment problems.

Cryotos CMMS Implementation

Cryotos CMMS enabled the company to overcome these challenges by digitizing and automating maintenance processes, resulting in better control and visibility across the plant.

Key Features and Benefits:

How Cryotos CMMS Tackles Daily Equipment Breakdowns

A few representative examples illustrate how Cryotos CMMS supports fast, structured resolution of equipment breakdowns:

Issue 1: Fire Alarm Panel Reset Failure

Details: The fire alarm panel fails to reset after activation, likely due to aging hardware or software issues requiring vendor intervention.

Solution: Coordinated with the vendor to repair the panel and performed a firmware update, restoring proper reset functionality.
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Issue 2: Forklift Fork Backrest Carriage Slightly Bent

Details: Minor bending detected on the forklift backrest carriage, potentially compromising load stability and safety.

Solution: Repaired the carriage by hydraulic straightening, restoring its safety and functionality.
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Issue 3: Compressor Overheating During Peak Operation Hours

Details: Frequent overheating observed, likely due to clogged filters and insufficient cooling.

Solution: Cleaned and replaced filters, improved ventilation, and scheduled more frequent maintenance checks to prevent recurrence.
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Issue 4: Conveyor Belt Misalignment Causing Frequent Stoppages

Details: Conveyor belt was misaligned, resulting in operational delays and potential product damage.

Solution: Realigned the conveyor belt and implemented routine alignment checks within the preventive maintenance schedule.

Results

Faster Issue Resolution
Easy complaint logging and real-time feedback have improved the speed and quality of issue resolution across the plant.

Stronger Operational Control
Accurate digital meter readings and shift-wise task tracking give management full visibility into utility usage and workforce performance.

Increased Equipment Reliability
Proactive preventive maintenance has improved equipment reliability and strengthened workplace safety.

Optimized Inventory Management
Precise tracking of spare parts usage prevents shortages and reduces unnecessary stock holding.

Greater Productivity & Compliance
Real-time data visibility and employee performance monitoring give the management team the insights needed to drive productivity, maintain safety compliance, and continuously improve operations across the organization.