When a machine stops,
the operator knows exactly what to do.
Step-by-step guidance on tablets. Breakdown procedures. Changeover SOPs. Training videos. MTTR drops 45%. Operators ramp up 60% faster.
MTTR Reduction
Faster problem solving
Ramp-up Time
New operator training
Guided Steps
Contextual procedures
Integrated
Part ordering built in
Six types of operator guidance.
From simple checklists to complex troubleshooting. Video, images, text — all accessible in real time on the floor.
Breakdown Guides
When a machine stops, the operator opens the breakdown guide on their tablet. Step-by-step procedure appears: photos, videos, parts list, expected time.
The result:
A breakdown that normally takes 2 hours now takes 70 minutes. Fewer callbacks to maintenance. Operators solve 60% of issues themselves.
Changeover SOPs
Changeover procedures documented with video, photos, timing expectations. No more improvisation. No more 'let's ask the experienced operator'.
The result:
Changeover time consistency improves 35%. Shift C's 24-min changeover becomes the standard for all shifts in 1 week.
Setup Procedures
Complex setup steps broken down: jig attachment, sensor calibration, material loading sequence. Visual guidance at every step.
The result:
Setup errors drop 70%. A setup that used to generate 10 scrap parts now generates 2. Cost savings: $1,500 per changeover.
Preventive Maintenance Checklists
Daily/weekly/monthly maintenance: what to check, how to check it, what values are normal, when to alert maintenance. Digital checklist, auto-logged.
The result:
Maintenance compliance improves from 60% to 95%. Preventive maintenance catches issues before breakdown happens.
Operator Troubleshooting Guides
Decision tree: 'Is the alarm a temperature warning? Follow path A. Is it a pressure alarm? Follow path B.' Guided diagnosis in real time.
The result:
Operators correctly diagnose 85% of issues now. Before: they guessed, called maintenance, guessed wrong, wasted time.
Video & Image Support
Complex procedures shown in video. Slow-motion shows finger positioning. Zoomed images show sensor alignment. No ambiguity.
The result:
An operator trained via video + images performs procedures 40% faster than one trained via text manuals.
A breakdown solved in 18 minutes instead of 2 hours.
Temperature warning on Machine A at 2:15 PM
Operator opens 'Temperature High' troubleshooting guide on tablet
Check coolant level → add coolant → check suction line → clear blockage if needed
Step 3 shows video of suction line check from previous training. Operator knows exactly what to look for.
Problem solved: blockage in suction line. Operator logs fix. Data is saved for trend analysis.
Machine returns to run. MTTR: 18 minutes. Maintenance alert not needed.
Everything built into every guide.
Step-by-step visual guidance with photos and video
Timer for expected completion time + alerts if duration exceeds estimate
Spare parts integrated: identify parts needed, order directly from the guide
Live support button: connect to maintenance or training on video call
Multi-language support: Spanish, Mandarin, Hindi auto-translat
Offline mode: guides work even without internet connection
Performance tracking: which steps take longest, where operators struggle, data for training
New operators become productive 60% faster.
Without Digital Instructions
- • 2 weeks of floor shadowing
- • Dependent on experienced operator availability
- • Knowledge loss when experienced operator leaves
- • High error rate in first 6 months
- • Inconsistent procedures between operators
With Digital Instructions
- • 4 days of combined training + digital guides
- • Consistent procedures for all operators
- • Knowledge preserved and easily transferable
- • Error rate matches experienced operators by week 3
- • Procedure updates auto-distributed to all
Cost benefit: Training cost per operator drops from $2,400 to $900. MTTR improves 45%. Maintenance callbacks drop 60%.
Operators become the first line of maintenance.
With clear procedures, most breakdowns don't reach your maintenance team. Operators solve them themselves. Maintenance focuses on what only they can do.
Breakdown Resolution
Operators solve without maintenance intervention
Avg MTTR
Down from 100+ minutes before digital guides
Preventive Compliance
Scheduled maintenance checklist completion
Empower operators with step-by-step guidance.
Breakdowns solved in 30 minutes. New operators ramp up in 4 days. Maintenance focuses on strategy, not fire-fighting.
Deploy Digital Work Instructions →