Mobile Maintenance Management – Digital Future of Maintenance

SPIE AUTOMATION developed a customized mobile maintenance management system for our customer in the automotive industry, consisting of an iOS app and a web-based management platform. The system connects 180 maintenance technicians with around 600 systems, communicates directly with the machines via an OPC interface, and sends fault messages or repair orders in real time via push notification to the responsible technician.

Fig.: Mobile Maintenance Management © SPIE AUTOMATION

Challenge and Objective

The initial situation at the customer’s site was characterized by a central control room that manually transmitted orders to all maintenance technicians via handheld radio – regardless of responsibility or location. This procedure did not allow parallel communication, made prioritization difficult, and offered no possibility for independent troubleshooting documentation. The goal was to replace the control center with a modern, intuitive software solution that personalizes work orders, accelerates communication channels, and bundles all maintenance planning in one central location.

Solution and project implementation

The implementation was carried out by the software development department of SPIE AUTOMATION and in close coordination with the customer. Initially, a function-oriented prototype was developed that connected to the existing fault reporting system. Initial tests helped to collect performance indicators and optimize interface requirements. Subsequently, the software was further developed agilely in three sub-releases – with short feedback cycles and flexible adaptation to new customer requirements. On the way to the final solution, several challenges had to be overcome: The existing fault system first had to be examined and understood in detail. In addition, it was necessary to keep the delay time between the occurrence of a fault on the system and the live display or push notification to the responsible maintenance technician as short as possible. Furthermore, a flexible assignment of iPhones and system groups to individual persons had to be ensured in order to personalize fault messages precisely. The solution includes an iOS App for the maintenance technicians, which sends push notifications, enables photo documentation and offers direct feedback on fault processing. It is complemented by a web-based management platform for foremen and shift supervisors, which provides tools for shift planning, responsibility overview, attendance planning, fault statistics and history view. Technologically, the system is based on a modern stack of MQTT, MSSQL, React (Material-Design, Mobile-First), C#, Swift, SignalR, REST, OPCDA, LDAP as well as automated integration tests and CI/CD.

Benefits

With the new system, work orders are processed completely digitally and in a personalized manner. Faults are immediately forwarded to the right person, which shortens reaction times and avoids duplication of work. The documentation – including photos – is done directly on the iPhone, which increases transparency and traceability. The central management tool considerably facilitates shift and resource planning, offers a clear overview of responsibilities and enables a statistical evaluation of the faults. This significantly improves efficiency, planning reliability and information flow in the maintenance process.

These SPIE AUTOMATION Strengths Were Applied

Fig.: Employee planning © SPIE AUTOMATION
Fig.: Fault comments © SPIE AUTOMATION
Fig.: Fault messages © SPIE AUTOMATION

Complex maintenance with lots of data, lots of users and lots of systems – that used to be confusing. Today, everything is intelligently linked and easily accessible.

Daniel Schmitt
Head of Software Development
SPIE AUTOMATION

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