Equipment & asset register
Maintain asset IDs, descriptions, categories, serial numbers, locations, installation dates, warranty details, criticality and lifecycle status. Organise plant, line, machine and component relationships.
Asset visibilityKnow what you own, where it is and its current condition.
Planned workOrganise preventive jobs around production priorities.
Parts readinessCheck spare parts before a job reaches the shop floor.
Performance insightTrack downtime, cost, response and repair trends.
Maintenance aligned with manufacturingPlan equipment care with a clear view of production needs.
More than a breakdown register
Turn equipment maintenance into a business advantage.
In manufacturing, one unavailable machine can affect an entire line: operators wait, work-in-progress accumulates, delivery dates move and costs rise. A connected ERP maintenance process helps teams plan work, record what happened and make better decisions using consistent asset history.
Solis System Maintenance Management is designed as a practical framework for manufacturers that need control over equipment, maintenance requests, work orders, schedules, labour, spares and performance—without losing sight of day-to-day production.
- Build a reliable register of machines, tools, utilities and critical components.
- Standardise preventive plans, inspections, checklists and repair procedures.
- Coordinate maintenance priorities with production, stores and purchasing.
- Capture labour, parts, downtime and service history for cost analysis.
Connected maintenance capabilities
Everything your maintenance team needs to stay in control
Manage the complete maintenance lifecycle—from the first operator observation through planning, execution, verification and performance review.
Preventive maintenance plans
Define recurring jobs by calendar frequency, operating hours, production cycles, meter readings or usage counts. Generate due work from approved maintenance plans.
Maintenance work orders
Create, prioritise, assign and track corrective, preventive, inspection, lubrication, calibration and shutdown work through clear statuses and approvals.
Breakdown & service requests
Let operators report an abnormal sound, leak, vibration or stoppage with the asset, symptom, urgency, shift and supporting notes. Convert approved requests into work orders.
Spare parts & maintenance stores
Check stock availability, reserve parts against jobs, record issues and returns, monitor minimum levels and initiate purchase requests for shortages.
Downtime & reliability analysis
Record failure start and end times, causes, repair duration and lost production. Review repeat failures, MTTR, MTBF, availability and maintenance cost trends.
A controlled maintenance lifecycle
From a shop-floor observation to verified completion
A consistent workflow makes ownership visible, improves handovers between shifts and creates a usable history for future planning.
1. Identify & request
Operator reports an issue or the system identifies work due from a maintenance plan or meter reading.
2. Review & prioritise
Planner checks safety, asset criticality, production impact, urgency and required skills.
3. Plan resources
Estimate labour, duration, tools, permits and spare parts; coordinate the maintenance window.
4. Execute & record
Technician follows the procedure, records findings, parts used, actual time and failure cause.
5. Verify & learn
Supervisor reviews work, asset is released for operation and the history updates for analysis.
Plan, execute and improve
Maintenance functions for real factory operations
Choose the process depth that fits your plant, while keeping a clear path to more advanced maintenance practices.
Asset hierarchy & component history
Link a machine to assemblies and maintainable components. See past repairs, replacements, inspections and recurring faults in one history.
Job plans & maintenance checklists
Standardise task steps, safety precautions, inspection points, tools, estimated hours and reference documents for repeatable work.
Calendar, shift & shutdown planning
Schedule work around shifts, planned production stoppages, technician availability and statutory or customer-required inspections.
Technician and contractor management
Assign responsible technicians, skill requirements, internal teams and external service providers; record attendance and actual work hours.
Material reservation & procurement
Plan spare parts in advance, reserve available stock, identify shortages and connect purchase requests to the maintenance requirement.
Inspection, calibration & compliance
Track inspection due dates, measurement results, pass/fail decisions, certificates, corrective actions and approvals where required.
Work order costing
Capture labour, consumed materials, contractor charges and other recorded expenses to compare planned and actual maintenance costs.
Mobile-friendly shop-floor updates
Give authorised users a practical way to view assigned jobs, check procedures, report findings and update work status near the equipment.
Advanced maintenance
Build maturity at a pace that makes sense for your plant.
Start with reliable asset data and disciplined preventive maintenance. Add condition monitoring and predictive techniques when your equipment, data quality and team readiness support them.
Plan your next step →Condition-based maintenanceUse inspection results, vibration, temperature, pressure or other condition indicators to trigger review.
Predictive insightsAnalyse trends and failure patterns to estimate risk and help prioritise intervention.
Connected equipment dataWhere integrations are available, bring meter readings and machine alerts into the maintenance workflow.
Guided recommendationsUse asset history, standard procedures and decision rules to support technicians and planners.
Advanced capabilities such as sensor connectivity, predictive analytics and automated alerts depend on the equipment, integrations, data availability and selected system configuration.
Maintenance maturity journey
Move forward in practical stages
Advanced maintenance is built on clean master data, good work-order discipline and dependable records—not technology alone.
Stage 01Reactive
Respond to failures, record repairs and establish an accurate equipment register.
Stage 02Preventive
Introduce recurring plans, checklists, due dates, work scheduling and spare-parts readiness.
Stage 03Condition-based
Use inspection readings and condition thresholds to make maintenance timing more responsive.
Stage 04Predictive & optimised
Use reliable history, connected data and analytics to improve risk-based maintenance decisions.
ERP-connected operations
Maintenance works better when departments work together
Maintenance does not happen in isolation. Connect the work order with the operational information required to prepare, execute and close the job.
Production planning
Coordinate planned maintenance windows with production schedules, line priorities and equipment availability. Communicate expected downtime before work begins.
Inventory & warehouse
Check on-hand and reserved quantities, identify part locations, issue components to work orders and return unused material with traceable transactions.
Procurement
Raise purchase requests for unavailable parts and services, follow supplier delivery status and help ensure critical items arrive before scheduled work.
Finance & costing
Provide a consistent basis for reviewing maintenance material, labour and service costs, with posting and accounting treatment determined by ERP configuration.
Quality & safety
Record inspection outcomes, permit checks, required approvals and corrective actions to support controlled, auditable maintenance execution.
HCM & workforce
Align assignments with technician availability, skills, shift calendars and training or certification requirements where applicable.
Operational outcomes
Measure what matters to your factory
Establish a baseline first, then use consistent measures to understand whether maintenance changes are improving operations.
Equipment availability
Understand when assets are ready for production and how downtime affects output.
Faster response & repair
Review time from request to response and the duration required to restore equipment.
Controlled maintenance cost
Compare planned and actual labour, materials, services and other recorded job costs.
Consistent execution
Monitor preventive work completion, overdue jobs, inspection compliance and repeat faults.
Maintenance KPIs
Turn work-order history into useful decisions.
Use common definitions across sites and departments so maintenance, production and management can discuss performance using the same facts.
- Review recurring breakdowns by asset, component, line, shift and failure code.
- Identify overdue preventive tasks and jobs waiting for material or approval.
- Compare planned hours with actual technician hours and repair duration.
- Use trends to prioritise root-cause analysis and improvement actions.
PERFORMANCE MEASUREWHY IT MATTERS
MTTR
Average time needed to restore equipment after a failure.
MTBF
Operating time between recorded failures; useful for tracking reliability.
Availability
How consistently equipment is ready when production needs it.
PM compliance
Whether scheduled preventive work is completed on time.
Unplanned downtime
Production time lost to unexpected equipment stoppages.
Maintenance cost
Recorded labour, parts and service cost by asset or period.
Built around manufacturing realities
Support a wide range of factory equipment.
Use a common maintenance process while tailoring plans and checklists to the equipment type, production environment and risk profile.
- Automotive & engineering: CNC machines, presses, welding cells, assembly lines and fixtures.
- Metal fabrication: cutting machines, compressors, cranes, furnaces and extraction systems.
- Food, chemical & process: pumps, motors, mixers, tanks, utilities and inspection-critical assets.
- Packaging & plastics: moulding machines, conveyors, chillers, printing and packing lines.
- Plant utilities: electrical panels, air systems, water systems, generators and facility equipment.
Standard process, equipment-specific plansAdapt maintenance procedures to the needs of each production environment.
Maintenance performance dashboard
See equipment performance at a glance.
Compact sample charts show how maintenance KPIs can be presented inside the ERP dashboard. The values below are illustrative demo data, not live plant results.
Overall Equipment Effectiveness (OEE)
78.4%
Availability × Performance × QualityTarget: 85%
Illustrative OEE calculation; define planned production time and exclusions consistently.
Unplanned downtime
12.6 hrs
Hours lost by dayGoal: reduce trend
Use downtime reason codes to identify repeat faults and high-impact assets.
Preventive maintenance compliance
92%
Completed by due dateTarget: 95%
Track overdue tasks and the reasons work could not be completed as planned.
Implementation approach
Start with the foundations. Improve continuously.
A staged rollout helps teams adopt the system without trying to digitise every maintenance process on day one.
Map assets & criticality
Clean up equipment lists, locations, asset hierarchy, criticality ratings, maintenance owners and existing service records.
Standardise work
Define request categories, priorities, work-order statuses, job plans, preventive frequencies, safety checks and approval rules.
Connect parts & people
Agree spare-part codes, minimum stock, reservations, technician skills, shifts and procurement hand-offs.
Pilot & train
Run a pilot on selected critical machines, train operators and technicians, and refine workflows from real feedback.
Measure & optimise
Review data quality, compliance, downtime and costs regularly. Add advanced monitoring only when the foundation is dependable.
Govern & improve
Assign ownership for master data, failure coding, KPI definitions, procedure revisions and periodic maintenance-plan reviews.
Frequently asked questions
Maintenance Management FAQs
What is Maintenance Management in a manufacturing ERP?
It is the structured management of equipment, maintenance requests, preventive plans, work orders, technicians, spare parts, repair history, costs and performance measures within the wider manufacturing operation.
What is the difference between preventive and corrective maintenance?
Preventive maintenance is scheduled before a known failure based on time, usage or cycles. Corrective maintenance addresses a fault or defect that has already been identified; it may be planned or urgent depending on risk and production impact.
Can maintenance work be planned around production?
Yes. A connected process can help planners coordinate work windows with production schedules, shift calendars, equipment availability and the parts or skills required. Actual integration depends on the ERP configuration.
How does maintenance management help control spare parts?
It links required materials to work orders, checks available stock, supports reservations and issues, identifies shortages and can initiate purchasing workflows for unavailable items.
Does advanced maintenance automatically predict every breakdown?
No. Predictive maintenance depends on suitable asset data, reliable history, meaningful condition signals and validated models or rules. It supports better decisions but cannot guarantee that every failure will be predicted.
Is this suitable for small and medium manufacturing companies?
A phased approach can suit SMEs: begin with asset registers, breakdown requests, work orders, preventive schedules and spare-parts control, then expand into reliability analytics and connected equipment data as needs grow.
Make every maintenance action count
Talk to Solis System
Ready to bring greater control to your plant maintenance?
Discuss your equipment types, current maintenance process, spare-parts challenges and reporting needs. Build a practical roadmap for connected maintenance within your manufacturing ERP.