Maintenance & machine care for the whole line
Tape lines, circular looms, lamination, flexo printers, cutting and stitching — log every breakdown, schedule preventive work by running hours, track spares, and see which machine is quietly costing you the most.
Maintenance is a module of Nexora ERP and ships with it today. Requests and how soon they were attended, breakdown, preventive and installation jobs with photos, notes for next time, spares issued from the store with their cost landing on the machine, the preventive schedule showing whose spares are ready and whose are short, and breakdown analysis by department and machine. It is one of the optional modules — switch it on per company, or leave it off.
Breakdown logging
Operator raises it from the floor; fitter closes it with cause, action, spares used and minutes lost. Nothing on paper.
Preventive schedules
Checklists by machine type, triggered by calendar or running hours read from production entries.
Spares & consumables
Spares stock, minimum levels, issue against a job, and machine-wise spares cost history.
Machine master
Every loom, extruder and printer with make, model, installation date, AMC, warranty and documents.
Downtime analysis
Downtime by machine, cause and shift; MTBF and MTTR; repeat failures flagged before they become habits.
Cost of downtime
Lost minutes × machine rate from the costing masters = what the breakdown actually cost, in rupees.
Downtime you can see in the same reports as output
Because the maintenance module reads the same machine master and production entries as the rest of Nexora, a loom's downtime shows up next to its output, its waste and its operator — not in a separate register nobody reconciles.
- Running-hour based preventive triggers, no manual meter reading
- Mobile-friendly for the fitter on the floor
- Works with staff tracking for fitter productivity
- Available standalone or as a Nexora ERP module
Typical machine set covered
What breaks in a woven sack plant, and what it costs you in output
A woven sack line is a chain, and the chain stops at its weakest machine. Tape extrusion feeds the looms, the looms feed lamination, lamination feeds printing, and printing feeds cutting and stitching. An hour lost at the extruder is not an hour lost at the extruder — it is an hour that the looms behind it eventually stand idle for.
That is why maintenance in this industry is not a spares register. It is a production question, and it has to be answered in the same report as output.
| Machine | What usually stops it | What it stops behind it |
|---|---|---|
| Tape extrusion line | Die build-up, filter changeover, take-up and winder faults, chill roll temperature | Every loom, once the tape stock runs down |
| Circular looms | Shuttle wear, reed and heald damage, tape breaks, bobbin change, bearing noise | Fabric roll supply to lamination and cutting |
| Lamination / extrusion coating | Die lines, chill roll marks, joint and web breaks, temperature drift | Every laminated and BOPP order |
| Printing | Cylinder changeover, registration, doctor blade, anilox cleaning, solvent handling | Printed dispatch, and the most expensive material in the plant |
| Cutting & stitching | Needle breakage, thread tension, cutter blade, folding alignment | Finished bag count, and the dispatch date |
| Bottom pasting | Glue system, patch feed, folding gear | Block bottom and valve orders |
Breakdown logging that a shift can actually do
Maintenance systems fail for one reason: the person on the floor will not fill them in. Nexora keeps the breakdown entry to what a supervisor can finish between two machines — machine, time down, time up, what happened, what was done, what was consumed. The reason is picked from your own list rather than typed, so that six months later the same fault is the same word and can be counted.
Preventive schedules that come to you
A preventive schedule is only preventive if somebody is told. Schedules run on running hours or on the calendar, whichever fits the machine — a loom on hours, a compressor on months — and the due list arrives on the dashboard rather than sitting in a register nobody opens. Overdue work stays visible until it is closed, with who closed it and when.
Spares, and the ones that always run out
Every breakdown records what it consumed, so the spares list stops being a guess. Over a few months the plant learns which parts it truly runs on — shuttles, reeds, needles, doctor blades, filters, belts — and which ones sat on the shelf for a year. Consumption ties back to the machine, so a single loom eating shuttles is visible as a machine problem rather than a stores problem.
Downtime in the same report as output
This is the part that changes decisions. Downtime by machine, by reason and by shift, set beside what that machine produced, answers the questions a plant actually argues about: which machine is really the bottleneck, whether the night shift loses more time than the day shift, whether a fault is getting worse, and whether the last repair held. A machine that is down for a short time every day costs more than one that is down for a day once — and only a report that counts both shows it.
It connects to the rest of the plant
Because maintenance sits in the same system as shop-floor tracking and inventory, a downtime record knows which operator was on the machine and which spare left the store. And because the ERP holds the production plan, a machine that is out of action is a machine the plan can be told about.