A CMMS (computerised maintenance management system) records every asset you maintain and everything done to it: breakdowns, work orders, preventive maintenance, spare parts and what they cost. In manufacturing it also has to answer the questions plant heads and auditors ask. Which assets fail most? How long do repairs take? Is planned maintenance done on time? IATF 16949 clause 8.5.1.5, for example, expects a total productive maintenance system with objectives such as MTBF, MTTR and preventive-maintenance compliance.
Zometric builds the record on an asset tree you define for each plant. You name the levels yourself, such as line, cell, machine and sub-unit, and an asset can sit under more than one parent. When a machine breaks down, its parents show as partly or fully down. A work order whose type needs a permit cannot start until a valid permit is attached. Every lifecycle change, scheduling lock and status change is kept with who made it and when.
An asset can be linked to its machine in Zometric Production. A breakdown on it then opens and closes a downtime period there too, so maintenance and production record the same stoppage. For regulated plants, a work-order type can require requalification (IQ, OQ or PQ). After that work, the asset stays locked until a qualification record is approved.
Six problems maintenance teams describe in their own words, and what changes when breakdowns, work orders and spares are records rather than notes.
From the asset tree to the KPI dashboard, every step writes to the same asset record.
Setup · Plant hierarchy
Name the hierarchy levels for each plant and choose which levels can have breakdowns logged against them. Then create asset types and assets, by hand or from a CSV file, with as many parents as each asset needs. Link an asset to its production machine where there is one.
Event · Breakdown
Pick the asset, then record the start time, the production impact and the failure mode. The asset is set to Down, its parents update, and it is locked for scheduling. In the same step you can create a corrective work order with a priority and an assignee.
Plan · Work order
Choose the type and a template with its checklist. Set a priority from Low to Critical, an assignee and a due date, and link a breakdown or a turnaround if there is one. The asset is locked for an open work order, and the due date is shown as the estimated release.
Safety · Permit to work
Record the permit number, the type (hot work, confined space, electrical isolation, working at height or general) and when it is valid from and to. Every permit appears in one permit-to-work register.
Execute · In progress
Tick checklist steps as they are done and log labour hours by technician and date. Book spare parts from the list that suits this asset or asset type. If the job is waiting for spares, move it to Pending Parts and back when they arrive.
Close · Completion
Completion checks the mandatory steps and saves the completion notes. The scheduling lock is released when no open breakdown or work order is left on the asset. If the type requires qualification, the lock stays until an IQ, OQ or PQ record is approved. Close the breakdown with its end time and root cause.
Prevent · PM schedules
Create PM schedules with a category, a template and an interval in days, and assign them to many assets at once. Log each execution with checkbox, measurement and text steps. The next due date is set from the completion date, and on-time results feed PM compliance.
Review · KPIs and alerts
The KPI dashboard and failure analysis show availability, MTBF, MTTR, the top failure modes and the assets that fail most. Alerts for recurring failures, low stock, sensor thresholds and out-of-range PM readings are acknowledged and resolved in one list.
Each capability is tied to a decision your team is already trying to make.
Any depth, with level names you define per plant (e.g. Plant → Line → Cell → Machine → Sub-unit), and assets that can sit under more than one parent. A breakdown marks every parent as partly or fully down.
Work-order types you define — corrective, preventive, turnaround and more — each able to require a permit to work or IQ/OQ/PQ requalification. Templates add checklists whose mandatory steps must be done before completion.
Time-based PM schedules with categories, checklists of checkbox, measurement and text steps, and bulk assignment to assets. Overdue and due-this-week PMs are listed, out-of-range readings raise alerts, and the next due date rolls forward from completion.
IoT devices post sensor readings to Zometric. Threshold rules above or below a limit raise alerts and can open a high-priority corrective work order automatically.
Centralised spare register, reorder alerts, consumption analytics and cost-per-asset tracking. Assets with an open breakdown or work order are flagged as locked for scheduling, with the reason logged.
Availability, MTBF, MTTR, PM compliance, work-order backlog, overdue work orders and spare-parts cost, live for any window, plus failure analysis by failure mode, category and the assets that fail most.
The KPI dashboard calculates reliability live from the breakdowns in the chosen window, 30 days by default. Availability is the time in the window minus breakdown time, divided by the time in the window. MTBF is the same uptime divided by the number of breakdowns, shown in days. MTTR is breakdown time divided by the number of breakdowns, shown in hours.
| Asset | Failure mode | Start | End | Minutes |
|---|---|---|---|---|
| CNC-03 | Failure modeSpindle bearing overheat | Start4 Sep 06:10 | End4 Sep 07:45 | Minutes95 |
| PMP-12 | Failure modeMechanical seal leak | Start11 Sep 14:20 | End11 Sep 16:40 | Minutes140 |
| CNC-03 | Failure modeSpindle bearing overheat | Start19 Sep 22:05 | End19 Sep 23:05 | Minutes60 |
| CMP-02 | Failure modeMotor overload trip | Start26 Sep 09:30 | End26 Sep 12:35 | Minutes185 |
| Total | Failure mode | Start | End | Minutes480 |
A maintained asset and a production machine can be the same physical record, so a stoppage is entered once.
When an asset is linked to a production machine, logging a breakdown opens a downtime period on that machine and closing the breakdown closes it. Production then holds the same stoppage.
Explore module →Logs and closes breakdowns, starts and completes work orders, ticks checklist steps, logs labour hours and books spare parts.
Raises and assigns work orders, creates PM schedules and their checklists, assigns them to assets, logs PM executions and plans turnarounds.
Issues permits to work against work orders and keeps the permit-to-work register.
Keeps the spare-parts register, reorder points and stock locations, and books receipts and stock adjustments.
Reads the KPI dashboard and failure analysis, acknowledges and resolves alerts, and sets up hierarchy levels, failure modes, work-order types and PM categories.
| Zometric Maintenance Management vs a spreadsheet and paper work orders | Spreadsheet and paper work orders | Zometric Maintenance Management |
|---|---|---|
| Breakdown record | A row typed after the shift, often with no cause | Logged against the asset with start time, impact and failure mode, and closed only with a root cause |
| Downtime | Estimated afterwards | Calculated in minutes from the start and end times |
| Recurring failures | Noticed when someone remembers | Same failure mode three times in 30 days flags the breakdown and raises an alert |
| Permit to work | A paper permit kept apart from the job card | A work order that needs a permit cannot start without one valid at that moment |
| Checklists | Ticked at the end, or never returned | Mandatory steps must be ticked before the work order can be completed |
| Spare parts | Shortages found when the shelf is empty | Every issue and receipt in a ledger, with a low-stock alert at the reorder point |
| MTBF and MTTR | Put together by hand each month | Calculated live from the breakdown log for any window |
| History | Cells overwritten | Every status change, lock and lifecycle change kept with user and time |
Load the asset register from a CSV file, starting from a sample. Each row can carry a code, name, type, one or more parents, serial number, manufacturer, model, location, commissioning date, useful life and purchase cost. Rows with errors are listed, and the rest are created.
IoT devices post readings as JSON with a sensor tag, a value and a timestamp. Each reading is checked against the sensor's threshold rules, which raise alerts and can open a corrective work order.
Import and export hierarchy levels, asset types, assets, components, sensors, threshold rules, spare parts, work-order templates and PM schedules as spreadsheet files from the administration screens.
Straight answers to the questions teams ask before a demo.
A CMMS (computerised maintenance management system) records the assets a plant maintains and the work done on them: breakdowns, work orders, preventive maintenance, spare parts and their cost. Zometric Maintenance Management is a CMMS for manufacturing. It is built on an asset tree you define for each plant and calculates MTBF, MTTR and availability from the breakdown log.
From the breakdowns in the chosen window, 30 days by default. MTBF is the time in the window minus breakdown time, divided by the number of breakdowns, in days. MTTR is breakdown time divided by the number of breakdowns, in hours. Breakdown time comes from each breakdown's start and end times, so nobody types it in.
Each work-order type can be set to require a permit. A work order of that type cannot move from Open to In Progress unless an active permit is attached that is valid at that moment. A permit records its number, type (hot work, confined space, electrical isolation, working at height or general), issuer and validity window.
Each breakdown can carry a failure mode from the plant's library. When the same failure mode occurs on the same asset three times within 30 days, the breakdown is flagged as recurring and an alert is raised. Each plant can change both numbers.
Yes. A work-order type can require qualification. When such a work order is completed, the asset is locked with a qualification hold, and that lock is not released automatically. It is released when a qualification record, such as IQ, OQ or PQ, is approved for the work order.
No. Spare parts are kept in a separate maintenance store with their own ledger, where every receipt, issue to a work order and stock adjustment is a permanent entry. Each spare has a reorder point and quantity, and can be linked to the asset types or individual assets it fits and to vendor part numbers with lead times.
Yes. Sensors are attached to asset components, and readings are posted to Zometric as JSON. A threshold rule fires when a reading goes above or below its limit. It raises an alert with the rule's severity and can be set to open a high-priority corrective work order automatically.
Yes, when the asset is linked to a production machine. Logging the breakdown opens a downtime period on that machine, and closing the breakdown closes it, so maintenance and production hold the same stoppage.
Zometric's modules share a single data backbone — adopting more of them compounds the signal-to-noise advantage.
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