HIDDEN LEAK #09 · PRODUCTION
The Machine Didn't Break Down Suddenly. Nobody Was Watching for the Warning Signs.
9 of 24 leaks diagnosed
No Warningbefore the machine simply stops
Most owners have never measured this on their own floor. needs real data
⚠️The Problem
Maintenance happens reactively, after a machine stops, because there's no maintenance calendar, no service history per machine, and spare parts stock isn't tracked until someone goes looking for a part that isn't there.
💥The Impact
- Production stops mid-run, sometimes mid-job, with no warning
- Spare parts get bought in a panic at markup prices, or the job simply waits
- There's no record of a machine's maintenance history to spot recurring failure patterns
🔍Root Cause
Maintenance and spare parts are tracked on paper or from memory, the production schedule just assumes every machine will be ready.
🔧The Fix
Planned maintenance only works if it's scheduled, tracked, and based on real machine use.
✅The Solution
- Machine-wise preventive maintenance calendar and history log
- Spare parts inventory with reorder alerts
- Breakdown log linked to machine and cause, to spot recurring issues
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People on payroll60
Per employee₹25,000
% of team time12%
Illustrative annual impact ₹21.6 L A directional estimate from your inputs, not a guarantee. Your real number comes from a 30-Day Automation Assessment.
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