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OperationsMaintenance and Quality

Keep plant equipment running and product within specification, from PM schedules to NCRs and CAPA.

Maintenance and Quality looks after your own production equipment and the quality of what you make. One half runs the equipment register, preventive and breakdown maintenance, spares and reliability; the other runs inspections with sampling, SPC, gauge calibration, non-conformance, CAPA and supplier quality. Stock, purchasing, people and money stay in the apps that own them.

Maintenance and Quality dashboard: open work orders, breakdowns, PM compliance, MTTR, inspection lots, first-pass yield and NCRs.

Key capabilities

  • Equipment tree with criticality and QR stickers
  • Time, meter and condition-based maintenance
  • Work orders with checklists, permits and costs
  • Incoming, in-process and final inspections
  • SPC charts, gauge calibration, NCR and CAPA
  • Supplier scorecards fed to Procurement
What it does

Maintenance and Quality in detail

Equipment and meters

Build a register of every machine, line, utility and instrument, with the information maintenance needs.

  • Plant, line, machine and component tree with the path on every record
  • Criticality scoring that sets default priority and spares flags
  • Warranty and AMC dates, linked Books fixed asset, documents and QR stickers
  • Counters and gauges with readings from web, mobile or a CSV and API import
  • Rule-based health score from age, breakdowns, PM compliance and condition

Preventive maintenance and work orders

Plan the work, approve the cost, schedule the right technician and record what was done.

  • PM plans by time, meter or whichever comes first, with fixed or floating schedules
  • Gauge limits that raise a predictive work order automatically
  • Requests from any employee, including by scanning the equipment QR
  • Checklists, failure codes, photos and work permits including LOTO
  • Technician board showing People shifts, leave, holidays and skills
  • Cost approval above a threshold, and labour logged to People timesheets

Spares, costs and reliability

Keep critical spares in stock and know what each machine costs to run.

  • Spares per equipment with min, max and reorder point per plant store
  • Automatic requisitions to Procurement when spares run low
  • Labour, spares and services costed per work order, equipment and plant
  • Close as expense or capitalise an overhaul, with a component asset registered in Books
  • Downtime, MTBF, MTTR and availability, with breakdowns feeding Manufacturing OEE

Inspections and sampling

Inspect what comes in, what is made and what goes out, and decide what to do with each lot.

  • Versioned inspection plans with characteristics, limits, defect classes and reaction plans
  • Incoming lots opened automatically from Inventory quarantine on receipt
  • In-process and final lots from completed Manufacturing operations
  • AQL single sampling based on ISO 2859-1, with tightened and reduced switching
  • Usage decisions that release or reject held stock, and a lot certificate usable as a CoA

SPC and calibration

Watch processes for drift and make sure the gauges measuring them can be trusted.

  • X-bar R, individuals and p charts with Western Electric rules
  • Cp, Cpk, Pp and Ppk capability
  • Gauge register with intervals, as-found and as-left readings and lab certificates
  • Overdue gauges blocked from use, and a list of inspections affected by a failed gauge

NCR, CAPA and supplier quality

Contain problems, find the root cause and stop them coming back.

  • NCRs from inspections, the shop floor, suppliers, customers and audits
  • Containment, disposition and cost of poor quality on each NCR
  • CAPA with 5-Why, Ishikawa, actions, verification and an effectiveness check
  • 8D report PDF for customer replies
  • Supplier scorecards with PPM and NCRs, SCARs emailed to vendors, and complaints linked to Support tickets
Built for India

Indian rules, built in

Templates and records reflect Indian statutory and accounting practice.

How Thoshika handles Indian compliance

  • Statutory PM templates for Factories Act examinations, boilers under IBR, HT installations and fire extinguishers, with competent person and certificate
  • NABL lab and certificate numbers on external calibrations
  • Service lines with SAC and GST rate
  • Capitalisation of major overhauls on the component approach of Ind AS 16 and AS 10
  • INR, IST and April to March reporting
Who uses it

Roles in Maintenance and Quality

Every person signs in once. Roles decide what they see, and can be limited to a location, branch or other scope where the app supports it.

Maintenance admin

Sets up plants, equipment and PM plans; approves, plans, schedules and closes work orders.

Maintenance technician

Raises requests and carries out assigned work orders, readings, labour and spares in their plants.

Quality manager

Owns inspection plans, sampling, usage decisions, NCR disposition, CAPA, gauges and supplier scorecards.

Quality inspector

Records inspection results and calibrations, decides lots within AQL, and raises NCRs.

Any employee

Reports a problem with equipment and follows their own requests.

See Maintenance and Quality with your own processes

Maintenance and Quality is available on its own or as part of Thoshika One, with every app for every employee.