Compiled Successfully Software Solution builds automated preventive maintenance notification platforms. Move beyond static calendar schedules: trigger maintenance reminders based on physical machine runtime hours, stroke counts, and operating cycles directly from PLC registers.
Most factories schedule preventive maintenance on arbitrary calendar intervals (e.g., 'grease bearing every 30 days'). However, a machine running 24/7 requires servicing much sooner than an identical backup machine that ran only 10 hours that month. Calendar-based servicing either wastes labor and parts or allows heavily used machines to run dry.
Manual hour meters and maintenance logbooks are rarely updated consistently. Technicians forget to record runtime, leading to missed lubrication intervals, filter clogs, and avoidable equipment breakdowns.
Without direct PLC hour-meter and stroke-counter integration, maintenance planners rely on guesswork or static calendar spreadsheets that fail to reflect true physical machine usage.
Our system reads internal PLC run-hour meters, part counters, and stroke registers continuously. When an asset approaches a pre-configured service milestone (e.g., 500 operating hours or 100,000 press strokes), the software dispatches automated mobile reminders, generates work orders, and escalates if servicing is delayed.
Industrial shop-floor implementation with sub-second PLC telemetry & automated ERP synchronization.
Our specialized application connects directly to machine controllers and enterprise systems without invasive code modifications, establishing deterministic real-time communication across industrial fieldbuses.
Transactional Buffer • RFC/BAPI Connectors • Protocol Translation (OPC UA, Profinet, Modbus, MQTT) • Store & Forward Caching
PLC Run-Hour Counter → Edge Gateway Milestone Check → Automated PM Work Order → Mobile Push Reminder → Technician Sign-Off → Reset Counter
Aligns maintenance directly with actual machine wear, optimizes technician labor, and guarantees that scheduled servicing is never overlooked.
Built for high-speed industrial environments where downtime is measured in seconds.
Triggers servicing based on actual PLC run hours, press strokes, or parts produced rather than arbitrary calendar dates.
Dispatches advance notifications at 90% threshold to allow maintenance planners to order required filters and seals.
Provides step-by-step digital inspection checklists on mobile devices, ensuring technicians follow standardized procedures.
Automatically escalates alerts to plant managers if mandatory safety or lubrication servicing exceeds grace periods.
Maintains an immutable digital log of every completed PM service, technician signature, and replaced component.
Supports hybrid rules (e.g., 'Service every 500 operating hours OR 60 calendar days, whichever occurs first').
Direct compatibility with leading global industrial automation and ERP ecosystems.
How data seamlessly flows from top-floor enterprise orders to shop-floor machine feedback.
The edge gateway reads retentive runtime meters and stroke counters from machine PLCs continuously.
The PM engine tracks accumulated usage against predefined service milestones (e.g., 250h, 500h, 1000h).
When an asset reaches 90% of its milestone, advance advisory notifications are dispatched to maintenance.
At 100% threshold, a formal PM work order is generated with required parts, lubricant specs, and SOP checklists.
The technician completes the service, checks off items in the mobile app, and the system logs service history.
Proven operational results across discrete and continuous processing plants.
Application: Press lubrication and die inspection alerts triggered every 50,000 strokes in Faridabad.
Application: Hydraulic oil filtration and screw inspection alerts every 2,000 run hours in Pune.
Application: Blister sealing heater and vacuum pump overhaul reminders in Baddi.
Application: CNC spindle lubrication and axis ball-screw inspection alerts in Manesar.
Why manual spreadsheets, point-to-point scripts, and isolated SCADA fall short.
| Evaluation Dimension | Traditional / Manual Methods | Compiled Successfully Platform | Operational Impact |
|---|---|---|---|
| Data Acquisition & Entry | Manual paper logbooks or end-of-shift spreadsheet entry | Sub-second automated PLC telemetry streaming & ERP posting | Zero transcription error; 100% real-time data integrity |
| Downtime & Alert Response | Local audible sirens in noisy shop floor; delays of 20-45 mins | Instant SMS, WhatsApp, and mobile push notifications with root-cause context | MTTR reduced by up to 50%; immediate intervention |
| Recipe & Parameter Download | Manual operator entry on HMI keypad; high risk of human error | Automated bidirectional recipe download from SAP order with 4-way handshake | Eliminates wrong recipe setups and expensive scrap batches |
| Architectural Resilience | Brittle point-to-point scripts without buffering; breaks on network drop | Industrial-grade Store-and-Forward with TLS 1.3 encryption | Zero telemetry loss even during enterprise network outages |
Engineered strictly according to international standards for industrial automation: ISA-95 enterprise-control integration, ISA-18.2 alarm management lifecycle, 21 CFR Part 11 electronic batch records, and TLS 1.3 / mTLS outbound cryptographic security. Built-in Store-and-Forward guarantees zero telemetry loss during network drops.
Connect a single production line in under 3 weeks with zero line disruption.
Request Pilot DemoTurnkey industrial automation and smart factory integration deployments across major industrial corridors in India.
Technical and operational answers for plant managers and automation engineers.
Discuss your PLC, SCADA, machine monitoring, IIoT or Industry 4.0 requirement with our industrial automation team. See how PLC events, SCADA alarms, machine downtime and industrial conditions can be monitored through web dashboards and mobile alerts.
