TPM
89 features
Total Productive Maintenance
Maintenance excellence. OEE-driven uptime.
Improve equipment effectiveness with preventive maintenance and OEE insights.
89
Capabilities
OEE
Tracking
Preventive
Plans
Why NexliOne
Engineered by ERP teams with 20+ years of enterprise delivery
Engineered by ERP teams with 20+ years of large-scale delivery across front-end, back-end, and business operations. NexliOne eliminates implementation and maintenance lock-in at scale.
Zero Implementation Cost
Free onboarding and configuration. No long consulting projects or surprise fees.
Minimal Maintenance
No extra hires required. Updates, security, and reliability are handled with you in mind.
All Advanced Features Included
Automation, analytics, and integrations are standard, not add-ons.
Start with One Module or All
Adopt exactly what you need now and scale to the full suite when you are ready.
89 Features Implemented
Search All Total Productive Maintenance Capabilities
Every feature below is fully implemented and production-ready. Search or filter to find exactly what you need.
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Showing 89 features
Real-Time OEE Monitoring
Monitor live OEE metrics with auto-refreshing dashboards (30-second intervals) showing real-time availability, performance, and quality gauges for each equipment.
Three-Component OEE Calculation
Track the three OEE components (Availability × Performance × Quality) with automatic calculation and breakdown analysis for targeted improvement efforts.
OEE Quality Benchmarking
Classify OEE performance against industry standards: World Class (≥85%), Good (60-84%), Fair (40-59%), and Poor (<40%) with visual badges and indicators.
Shift-Based OEE Tracking
Record and analyze OEE metrics by shift (Day, Evening, Night) to identify performance variations and implement shift-specific improvement initiatives.
Production Counter Tracking
Monitor total pieces produced, good pieces, and defects in real-time with target vs. actual tracking and status indicators (On Target / Below Target).
OEE Trends & Historical Analysis
Visualize OEE performance over time with daily, weekly, and monthly trend aggregation, change analysis, and export functionality for deeper insights.
Target Reference Lines
Set and display OEE targets on trend charts to clearly visualize performance gaps and track progress toward world-class manufacturing goals.
Equipment Selection & Filtering
Filter OEE data by specific equipment or equipment groups with flexible time period selection (7 days, 30 days, 90 days, custom) for focused analysis.
Preventive Maintenance Scheduling
Create comprehensive maintenance schedules with configurable frequency intervals (Daily, Weekly, Monthly, Quarterly, Annually) and automatic next-due-date calculation.
Maintenance Type Categorization
Organize maintenance activities by type (Preventive, Predictive, Corrective, Emergency) for accurate tracking, reporting, and resource allocation.
Overdue Detection & Alerts
Identify overdue maintenance immediately with color-coded warnings and visual indicators, ensuring timely completion of scheduled maintenance tasks.
PM Template Library
Build reusable maintenance procedure templates with versioning, skills requirements, parts lists, safety precautions, and estimated durations for consistent execution.
Task List Management
Define detailed task sequences for each maintenance schedule with step-by-step instructions, enabling technicians to complete work accurately and efficiently.
Technician Assignment & Scheduling
Assign qualified technicians to maintenance schedules based on skills and availability, with estimated duration tracking for effective resource planning.
Maintenance History Tracking
View complete historical records of all maintenance executions including actual vs. estimated time, parts used, costs incurred, and technician notes.
Performance Metrics per Technician
Track individual technician performance metrics including completion rates, time accuracy, and quality of work to optimize workforce allocation.
Complete Work Order Lifecycle
Manage work orders from creation through completion with status tracking (Open, In Progress, Completed, Cancelled) and full audit trail documentation.
Priority-Based Scheduling
Assign priority levels (Low, Medium, High, Critical) to work orders ensuring urgent equipment issues receive immediate attention and proper resource allocation.
Work Order Calendar View
Visualize all scheduled work orders on a monthly calendar with priority-based color coding and status indicators for effective maintenance planning.
Actual vs. Scheduled Tracking
Compare scheduled start/end dates with actual completion times to improve estimation accuracy and identify scheduling optimization opportunities.
Parts Usage & Cost Tracking
Record parts used and costs incurred during work order execution, building accurate equipment maintenance cost histories for budgeting and ROI analysis.
Technician Notes & Updates
Capture detailed technician observations, findings, and recommendations during work order execution for knowledge sharing and future reference.
Work Order Type Classification
Categorize work orders by type (Preventive, Corrective, Predictive, Emergency) to analyze maintenance patterns and optimize your maintenance strategy.
Complete Equipment Registry
Create and manage detailed equipment records including equipment number, name, type, location, manufacturer, model, and serial number with comprehensive specification tracking.
Equipment Status Management
Track equipment lifecycle states including Operational, Maintenance, Breakdown, and Retired with real-time status updates and visual indicators across your facility.
Equipment Criticality Classification
Classify equipment by criticality level (Critical, Important, Standard) to prioritize maintenance resources and ensure your most important assets receive appropriate attention.
Asset Hierarchy Visualization
Visualize parent-child equipment relationships in an expandable tree view, enabling clear understanding of equipment groupings and dependencies across your operations.
Equipment-Specific OEE Trends
Monitor OEE performance trends for individual equipment, tracking failure history and breakdown timelines to identify reliability patterns and improvement opportunities.
Spare Parts Inventory Integration
Link spare parts directly to equipment with part numbers, quantities, lead times, and stock status indicators to ensure parts availability for maintenance activities.
Critical Parts Identification
Flag critical spare parts and track stock levels (In Stock, Low, Out of Stock) to prevent production delays due to parts unavailability during breakdowns.
Downtime Event Logging
Capture downtime events with precise start/end times, automatic duration calculation, and category classification for comprehensive downtime analysis.
Downtime Reason Code Library
Define standardized downtime reason codes (Planned, Unplanned, Setup, Changeover, Breakdown, Idle) with OEE category linkage for consistent tracking.
Six Big Losses Tracking
Monitor and analyze the industry-standard Six Big Losses: Breakdowns, Setup & Adjustments, Small Stops, Reduced Speed, Defects, and Startup Losses.
Loss Impact Quantification
Track duration and quantity affected for each loss event with automatic OEE impact calculation to prioritize improvement efforts by business impact.
Pareto Analysis & Charts
Visualize cumulative loss impact with Pareto charts to identify the vital few issues causing the majority of equipment effectiveness losses.
OEE Impact Categorization
Link each downtime event and loss to specific OEE components (Availability, Performance, Quality) for accurate root cause attribution.
Autonomous Maintenance Hub
Centralized dashboard showing daily inspection completion, open findings, overdue schedules, and in-progress inspections for operator maintenance management.
Digital Checklist Builder
Create customized checklists for different equipment types including CIL (Cleaning, Inspection, Lubrication), Pre-Start, Post-Operation, and Safety checks.
Multi-Type Check Items
Define check items with various response types: Visual inspection, Measurement capture, Pass/Fail assessment, and Numeric Range validation with expected values.
Photo Documentation Requirements
Specify photo requirements for visual checks and enable photo capture during inspections for clear documentation of equipment condition and issues.
Critical Item Flagging
Flag critical checklist items requiring immediate attention when failed, ensuring serious equipment issues are escalated and addressed promptly.
Inspection Execution & Tracking
Execute inspections with pass/fail responses, numeric measurements, photos, and notes while tracking completion status and operator performance.
Findings Management & Escalation
Track issues raised from failed checklist items with severity classification (Low, Medium, High, Critical) and automatic escalation to work orders.
AM Schedule Management
Assign checklists to equipment with configurable execution frequencies and completion rate tracking for comprehensive autonomous maintenance programs.
Checklist Versioning
Maintain version control for checklists enabling updates while preserving historical records for audit trails and continuous improvement.
Complete 8-Pillar Implementation
Implement the industry-standard TPM framework covering all eight pillars: Autonomous Maintenance, Planned Maintenance, Quality Maintenance, Focused Improvement, Training & Education, Safety/Health/Environment, Administrative Management, and Equipment Improvement.
Pillar Progress Tracking
Monitor implementation progress for each TPM pillar with status indicators (Active, Planned, Not Started) and performance metrics to guide your TPM journey.
Focused Improvement (Kaizen) Projects
Manage Kaizen projects with structured methodology including problem statements, root cause analysis (5-Why, Fishbone), before/after metrics, and savings calculations.
Kaizen Category Classification
Categorize improvement projects by focus area (Availability, Performance, Quality, Safety, Cost Reduction) for targeted improvement portfolio management.
Improvement Status Workflow
Track Kaizen projects through standardized stages: Proposed → Approved → In Progress → Completed/Cancelled with team assignments and timeline management.
Before/After Metrics Comparison
Document baseline performance data and target improvements with quantified results comparison to demonstrate ROI from improvement initiatives.
Action Items & Team Management
Define step-by-step action plans with cross-functional team assignments, due dates, and progress tracking for effective project execution.
Quality Defect Tracking
Track quality defects linked to OEE quality metrics with trend analysis to identify equipment-related quality issues.
Prevention vs. Detection Metrics
Monitor the balance between defect prevention and detection activities to shift focus toward proactive quality assurance.
Rework & Scrap Tracking
Quantify rework and scrap resulting from equipment-related quality issues to calculate true quality costs and improvement ROI.
SPC Integration Points
Connect with Statistical Process Control systems to correlate equipment performance with quality outcomes for root cause analysis.
Quality-Focused Kaizen Projects
Launch and track improvement projects specifically targeting quality losses for systematic quality improvement.
Safety Inspection Management
Conduct and document safety inspections (Routine, Pre-Start, Incident Follow-up, Regulatory) with hazard identification and finding documentation.
Hazard Identification & Counting
Track hazards discovered during inspections with severity assessment and photo evidence for comprehensive safety documentation.
Corrective Action Tracking
Assign and monitor corrective actions for safety findings with status tracking to ensure timely resolution of safety concerns.
Near-Miss Reporting & Analysis
Capture near-miss incidents for proactive safety improvement, enabling analysis of potential hazards before they cause injuries.
LOTO Procedure Management
Document and manage Lock-Out/Tag-Out procedures for equipment maintenance to ensure worker safety during maintenance activities.
Regulatory Compliance Documentation
Schedule and track regulatory inspections with signoff workflows and approval processes to maintain compliance with safety regulations.
Comprehensive Skill Library
Define skills across categories including technical competencies, safety certifications, equipment-specific training, and general competencies for workforce development.
Training Record Management
Track employee training completion with certification numbers, trainer assignments, and proficiency levels (1-5 scale) for skills verification.
Certification Tracking & Expiry
Monitor certification status (Active, Expired, Revoked) with expiry date management to ensure workforce compliance and timely recertification.
Skill Matrix Visualization
View competency levels by employee across all defined skills to identify training gaps and plan development programs effectively.
Equipment-Specific Training Links
Associate required training and certifications with specific equipment to ensure only qualified operators perform maintenance on critical assets.
Competency Gap Analysis
Identify skill gaps across your workforce compared to job requirements to prioritize training investments and development programs.
Real-Time KPI Dashboard
Monitor equipment status distribution, OEE performance, and maintenance health at a glance with live KPI cards showing critical metrics across your entire operation.
Due vs. Overdue Maintenance Tracking
Stay ahead of maintenance backlogs with visual counters distinguishing overdue tasks from upcoming maintenance windows, ensuring nothing falls through the cracks.
Open Work Orders & Findings Summary
Instantly see all active work orders and open findings requiring attention, enabling rapid response to equipment issues and minimizing unplanned downtime.
Activity Feed & Quick Actions
Track recent inspections and work orders in real-time while accessing quick-action buttons to schedule preventive maintenance or create new work orders instantly.
Equipment Reliability Reports
Calculate and track MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair) metrics to measure and improve equipment reliability.
Maintenance Cost Analysis
Track planned vs. emergency maintenance costs, labor and parts expenses, cost per operating hour, and budget vs. actual comparisons.
Preventive Maintenance ROI
Calculate return on investment for preventive maintenance programs by comparing PM costs against avoided breakdown costs.
Operator Performance Reports
Monitor work order completion rates, inspection completion, average task duration vs. estimates, and training/certification compliance.
Trend Analysis & Comparisons
Compare performance across equipment, time periods, shifts, and operators to identify best practices and improvement opportunities.
Export & Sharing Capabilities
Export reports in multiple formats for sharing with stakeholders, integration with other systems, and offline analysis.
Failure Code Library
Build a standardized failure code taxonomy with categories (Mechanical, Electrical, Pneumatic, Hydraulic, Software, Operator Error) and severity levels.
Standard Repair Time Estimates
Associate expected repair durations with failure codes for accurate work planning and performance measurement.
Downtime Reason Configuration
Define and manage downtime reason codes with OEE category linkage for consistent downtime tracking and analysis.
Flexible Shift Configuration
Configure shift definitions with start/end times, break durations, and day-of-week assignments supporting 24/7 operations.
Multiple Shifts per Day
Support operations with multiple shifts including overlapping shifts and varying schedules for complex manufacturing environments.
Inventory Management Integration
Connect with inventory systems for spare parts availability, automatic reservation for planned maintenance, and usage tracking.
Financial System Integration
Link maintenance costs to financial management for budget tracking, cost center allocation, and maintenance spending analysis.
HR System Integration
Integrate with HR systems for employee skills, training records, and certification management for unified workforce data.
Real-Time Analytics
Connect with ClickHouse analytics for advanced dashboards, custom reports, and deep-dive analysis of maintenance performance.
Event-Driven Notifications
Leverage Kafka messaging for real-time notifications on equipment status changes, work order updates, and maintenance alerts.
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Drive uptime and performance every shift.
Unify preventive, corrective, and autonomous maintenance in one system.