Stop maintaining by calendar. Start maintaining by condition.
OpsSense joins the asset registry, live sensor data, and failure history into one picture per asset. The Asset Reliability Agent watches it around the clock and tells you which machine needs attention, when, and why — with the evidence attached.
The problems this solves
- Critical assets fail with no warning while non-critical ones get over-serviced on the same calendar
- Condition data lives in SCADA, route-based readings, and a historian nobody queries — never joined to the work history
- Asset criticality rankings exist in a slide deck, not in the system that schedules the work
- Repair-versus-replace decisions are made on anecdote because lifecycle cost per asset is unknowable
- OEM-recommended PM intervals are followed blindly, whether the asset runs one shift or three
Illustrative targets — customer-validated figures pending publication.
How OpsSense runs it.
One registry, full hierarchy
Every asset with its location, criticality, BOM, warranty, and complete work and cost history — from site down to component.
Condition monitoring built in
OpsSense Vibra and Therma stream vibration and temperature from rotating equipment; SCADA and historian tags join over OPC-UA and Modbus.
Failure predicted, not discovered
The Asset Reliability Agent baselines each asset, detects degradation, names the likely failure mode, and opens the work order weeks ahead.
A living model of the plant
The digital twin ties sensors, work orders, and documents to each asset's place in the system, so impact analysis is a click, not a meeting.
Lifecycle cost, per asset
Acquisition, maintenance, downtime, and energy cost accumulate per asset — so repair-versus-replace is a calculation.
Reliability KPIs from real data
MTBF, MTTR, availability, and bad-actor rankings computed from actual work records and runtime, per asset class and per site.
See your operations run themselves.
A 30-minute walkthrough with an operations engineer. Your assets, your workflows, your questions.