How a Leading Textile Manufacturing Company Eliminate Paper-Based Maintenance with Cryotos CMMS?

Company Overview

Page Industries: An Industry Leader in Innerwear and Leisurewear

Page Industries, an Indian company founded in 1994, has grown into a leading name in the apparel industry, particularly in the innerwear and leisurewear segments. As the exclusive licensee of a leading global innerwear and leisurewear brand in India, Sri Lanka, Bangladesh, Nepal, and the UAE, Page Industries has successfully brought the global brand to the forefront of the Indian market.

Given the scale of operations and the critical role of machinery and equipment in manufacturing, maintenance management is crucial for Page Industries. The company aims to minimize downtime, reduce maintenance costs, and improve asset reliability and lifespan. Implementing a Computerized Maintenance Management System (CMMS) can address these needs by streamlining maintenance activities, tracking asset performance, and facilitating proactive maintenance strategies.

Business Problems


1. Maintenance Management:

  • Maintenance management was disjointed because there wasn't one unified system in place. For instance, while SAP was used for managing spare parts and various operations, preventive maintenance and breakdown still relied on a paper-based system.
  • The lack of integration between these systems resulted in inefficiencies in the overall maintenance process.
  • The disjointed approach hindered the seamless execution of maintenance tasks, leading to delays and increased operational challenges.
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2. Paper – Based management:

  • All maintenance activities were recorded on paper, making it difficult to monitor.
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3. Decision Making:

  • Advanced analytics are required to support proactive monitoring and maintenance decision-making.
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4. Asset Tracking:

  • The manual process for approving spare parts leads to extended equipment downtime and an increase in Mean Time to Repair (MTTR).
  • Without automated solutions, changeover times are significantly prolonged, impacting overall productivity.
  • Frequent asset transfers between locations were going untracked, leading to inefficiencies and potential asset mismanagement.
  • The lack of real-time monitoring for asset movements resulted in delayed responses to equipment needs, further contributing to operational challenges.
  • Additionally, the absence of a centralized system for tracking approvals and transfers increased the risk of errors and miscommunication.
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5. Inventory Management:

  • The spare parts consumed by the maintenance team during the breakdown were not recorded in a timely manner.
  • The spares transferred from the main warehouse to the sub-warehouse were not tracked.

Solution By Cryotos CMMS


Digital System for maintenance:

  • Cryotos offers a scalable software solution, now fully implemented as a unified system across all Page Industries plants to manage maintenance operations seamlessly.
  • The digitization of the entire maintenance process has eliminated the need for paper-based manual approaches, allowing for efficient management of assets, preventive maintenance schedules, and work requests through both the Cryotos CMMS web and mobile apps.
  • The integration of a QR code-based mobile app enables quick and easy access to maintenance data directly on the shop floor, enhancing real-time decision-making and responsiveness.
  • The system’s scalability and flexibility have also facilitated easy adaptation to Page Industries' growing operational needs, ensuring consistent performance across all facilities.
  • Additionally, the comprehensive reporting and analytics features provided by Cryotos have empowered Page Industries to make data-driven decisions, leading to continuous improvements in their maintenance processes.


Inventory Integration:

  • Seamlessly integrated with SAP for streamlined spare procurement and service requisitions, ensuring smooth and efficient operations.
  • All inventory movements, both inbound and outbound, are meticulously tracked in real-time, including detailed unit cost information, providing complete visibility and control.
  • The procurement process for new inventory has been significantly simplified, with enhanced tracking capabilities, leading to better inventory management and reduced lead times.
  • Integration has also enabled automated reporting and analytics, offering insights into inventory trends and optimizing procurement strategies.

Key Assets Managed

  1. S/N Switch: S/N Lock Switch, S/N Chain Switch, S/N Lock Switch with edge cutter, etc.
  2. Electrical Machines: Portable Boilers, Thread Winding, UPS, Transformers, Vacuum Iron Tables, Pad Printing, Heat Transfer Machines, Needle Detectors, Fusing Machines, etc.
  3. Mechanical Machines: Over Lock Machines, Flat Seamer, Racing Device, Pattern Trackers, Bar tack Machines. Etc.

Benefits Realized

  1. The maintenance history of each piece of equipment is tracked and recorded digitally.
  2. Spare usage tracking maintains and notifies minimum stock levels with real-time notifications.
  3. Cryotos' powerful workflow mechanism allows for a multi-level approval process for spares based on cost, thereby improving breakdown time and significantly reducing MTTR.
  4. Cryotos' customizable drill-down dashboard provides users with a transparent overview of the actual maintenance status of each department.

Key Metrics and Results

Priority Area Weight Priority Area Weight
Enhanced Equipment Reliability 30% Data-Driven Decision Making 10%
Preventive Maintenance 20% Maintenance Analytics 6%
Real-time Monitoring 10% Predictive Maintenance 4%
Improved Production Efficiency 20% Workforce Efficiency 7%
Downtime Reduction 12% Task Management 5%
Optimized Maintenance Schedules 8% Training and Knowledge Management 2%
Cost Savings 15% Scalability and Flexibility 5%
Reduced Maintenance Costs 10% Scalability 3%
Inventory Management 5% Customization 2%
Compliance and Quality Control 10% Sustainability Initiatives 3%
Regulatory Compliance 6% Energy Efficiency 2%
Quality Assurance 4% Waste Reduction 1%


Customer Feedback

"Adopting Cryotos CMMS has revolutionized how we handle maintenance, inventory, and mobile processes. The platform's automation of scheduling, seamless work order management, efficient inventory control, and mobile accessibility for our technicians have greatly enhanced our operational efficiency. This has led to a notable reduction in response times and minimized equipment downtime. The system's intuitive design and customizable features have made it straightforward for our team to integrate and utilize, leading to better service outcomes and increased customer satisfaction."

Conclusion

By utilizing Cryotos CMMS Software, Page Industries significantly enhanced their maintenance, inventory, and mobile operations, ensuring top-tier service quality and operational efficiency. The effective automation and management of maintenance tasks, maintenance of optimal inventory levels, and provision of mobile access to technicians were critical in minimizing downtime, accelerating response times, and reducing operational expenses. The user-friendly interface, flexibility, and customizable features of Cryotos played a crucial role in the seamless implementation and widespread adoption of the software throughout the organization.

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Don't Take Our Words!
Here From Our Esteemed Clients!

Gurit, supplier for composite materials, engineering services and equipment for the wind turbine | Client of Cryotos
Mr. Mohanmurali R

I recently purchased Cryotos CMMS Software for asset management needs at my organization and after a few months of testing and monitoring, I'm incredibly pleased with the results. The software is user friendly, accessible and the design is very intuitive. It covers all the aspects of managing maintenance and repair, starting from preventive maintenance and standardizing operation cycles, to scheduling and streamlining workflows. I am highly satisfied with the performance and the range of features offered by Cryotos. Highly recommendable!

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Al Zain Poultry Farms LLC, leader in poultry industry offering 100% halal and hygienically packed - Client of Cryotos
Mr. Vishnu S Nair

Since we've started using Cryotos, our team has been able to stay on top of all the various SOPs. Checklists and safety procedures are now easily accessible to everyone, and we can quickly reference them whenever we need to. The software has definitely helped to improve our team's communication and efficiency. Plus, the fact that it's cloud-based means we can access it from anywhere, which is a big plus. It has been a great help in keeping everyone on the same page and up to date with the latest procedures.

Ardelisys, security system installation service - Client of Cryotos
Mr. Sathyendran R.

I am using this application right now for my service team, very good, user friendly, have lot of customisation in workflow and service reports. the team supported for initial implementation, They have good support team. Myself fully recommended this application.

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