Downtime is the most expensive thing in your plant
OpsSense pairs a full CMMS with its own vibration and energy sensors, so failures announce themselves weeks before the line stops.
What this actually looks like on the ground.
- Unplanned downtime eats OEE, and the root cause is usually a bearing that had been screaming for three weeks.
- PM schedules run on calendar time, not runtime or condition, so half the PMs are wasted and the critical ones come late.
- Wrench time is lost to parts hunting — the technician arrives, the spare is not in the crib, and the machine waits.
- Tribal knowledge walks out with senior technicians; failure history lives in a retired supervisor's head.
- The CMMS, the historian, and SCADA do not talk, so nobody sees the full picture of a single asset.
- Shutdown scope creeps because condition data was never collected between turnarounds.
How OpsSense runs this industry.
Condition monitoring with Vibra
OpsSense Vibra sensors mount on motors, pumps, and gearboxes. Vibration and temperature stream to the Asset Reliability Agent, which flags degradation before functional failure.
Runtime and meter-based PM
Trigger PMs on runtime hours, cycle counts, or condition — not just the calendar. High-utilization assets get attention first.
Work orders with full asset history
Every job carries the asset's failure history, SOPs, and last readings. Technicians stop diagnosing from zero.
Spares tied to assets and BOMs
Critical spares are linked to the equipment they serve. Reorder points reflect lead times, and stock-outs are predicted, not discovered.
SCADA, historian, and ERP fabric
Read tags over OPC-UA and Modbus, sync costs and purchasing with SAP, Oracle, or Dynamics. One data model across OT and IT.
Energy per line with Volta
Volta meters on panels and feeders show energy per line and per shift. The Energy Agent flags idle-load waste and abnormal draw.
The AI staff for this industry.
Illustrative targets — customer-validated figures pending publication.
From vibration signature to closed work order
- 01
A Vibra sensor on the packaging line's main drive motor detects rising bearing-frequency vibration over ten days.
- 02
The Asset Reliability Agent correlates it with runtime from SCADA and raises a P2 work order with the diagnosis attached.
- 03
The Inventory Agent confirms the bearing is in the crib and reserves it against the work order.
- 04
The maintenance planner slots the job into Thursday's planned line stop and assigns the mechanical technician.
- 05
The technician replaces the bearing, logs readings and photos on mobile, and closes the order.
- 06
Post-repair vibration confirms return to baseline; the failure mode is written back to the asset's history.
- 07
The Executive Reporting Agent includes the avoided-downtime estimate in the monthly plant report.
OpsSense is designed to support ISO 55001-aligned asset management practices and maintains full audit trails on work, calibration, and safety-related tasks. Data residency options include in-Kingdom private cloud, and the platform is PDPL-ready for personal data handled in Saudi Arabia.
“We stopped arguing about whether a machine was about to fail. The sensor data settled it, and the work order was already open.”
See your operations run themselves.
A 30-minute walkthrough with an operations engineer. Your assets, your workflows, your questions.