One system across 14 sites: cold chain protected, MHE fleet uptime up 9 points
National logistics and distribution operator, Saudi Arabia. A logistics operator running distribution centers and a cold-chain network across the Kingdom consolidated maintenance from site-level spreadsheets into one platform. Continuous temperature assurance and a managed forklift fleet program followed within two quarters.
Illustrative targets — customer-validated figures pending publication.
The situation
The operator ran 14 distribution centers, a chilled and frozen network, and a fleet of several hundred forklifts and reach trucks. Each site managed maintenance its own way — two used aging local software, the rest used spreadsheets and a contractor's monthly report. Head office could not answer basic questions: fleet availability by site, cost per asset, or whether dock doors and refrigeration plants were being maintained to schedule.
Cold-chain compliance was the sharpest pain. Temperature logging was manual — clipboard rounds twice per shift — which satisfied the letter of audit requirements while leaving hours-long blind windows. Two product-loss incidents in one year, both discovered after the fact, put the problem on the executive agenda.
What changed
The operator standardized on OpsSense across all 14 sites in two waves. Assets were registered site by site with a common hierarchy and naming standard, so fleet, refrigeration, dock equipment, and building systems report into one model. The MHE fleet moved to meter-based PM driven by operating hours, with technicians completing checklist work on mobile and parts consumption tracked per truck.
Every cold room and refrigerated dock received Therma sensors reporting through Edge gateways, with Volta meters on refrigeration plant power. The Facilities Agent enforces temperature envelopes continuously: a drift raises an alert, a sustained excursion creates a priority work order and notifies the site duty manager, and every reading lands in an audit log that replaces the clipboard rounds. Trace GPS units on high-value yard equipment closed a long-standing visibility gap.
The result
Fleet availability rose nine points within two quarters, driven less by any single fix than by the boring mechanics working: hour-based PMs generated on time, parts kitted before service, and repeat offenders visible and dealt with. Head office now reviews one weekly dashboard — availability, PM compliance, cost per asset, open critical work — with every site measured the same way.
On the cold chain, temperature excursions reaching product-risk thresholds fell 42 percent, and those that occur are caught in minutes rather than at the next clipboard round. Audit preparation, previously a two-week document hunt per site, is now an export. The operator has since written continuous monitoring into its customer SLAs — turning a compliance burden into a commercial differentiator.
“Cold chain is a license to operate. Before, we proved compliance with clipboards and hoped. Now every cold room logs itself every few minutes, and an out-of-range condition becomes a work order before the load is at risk.”
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