Maximize Equipment Uptime. Minimize Unplanned Downtime.
FacilityFlow's AI-powered predictive maintenance helps manufacturing facilities achieve 89% OEE, reduce unplanned downtime by 68%, and extend asset lifespan by 30%—all while cutting maintenance costs by 25%.
Manufacturing Challenges That Drive Up Costs
Unplanned Equipment Failures
Production lines stop without warning, forcing emergency repairs that cost 3–5x more than planned maintenance. Each hour of downtime can cost $50K–$100K, with average failures exceeding $250K in losses.
Inefficient PM Schedules
Time-based maintenance wastes labor on healthy equipment while missing early warning signs on stressed assets. PM compliance averages just 65%, and up to 35% of PM work is unnecessary.
Spare Parts & Inventory Issues
Critical parts aren’t available when failures occur, while excess inventory ties up capital. Emergency orders with 300% markups are common, driving over $180K in avoidable inventory costs.
Paper-Based Maintenance Systems
Work orders get lost, maintenance history is fragmented, and teams lack real-time visibility. Compliance reporting becomes a manual nightmare, wasting 15–20 hours per week on admin work.
From Reactive to Predictive: The FacilityFlow Advantage
Predict Failures Before They Happen
FacilityFlow predicts equipment failures 7–30 days in advance with up to 97% accuracy, allowing teams to act before breakdowns disrupt production.
Planned, Cost-Effective Repairs
Replace emergency fixes with planned maintenance at optimal times. Reduce repair costs, avoid production halts, and keep schedules on track.
Optimized Parts & Labor Allocation
Gain full visibility into spare parts and asset health. Stock the right parts, reduce excess inventory, and eliminate costly last-minute orders.
Centralized, Digital Maintenance System
All work orders, asset history, and compliance documentation live in one system with real-time insights—no spreadsheets, no clipboards, no guesswork.
Built Specifically for Manufacturing Operations
🤖 AI Predictive Maintenance
Machine learning models analyze equipment data to predict failures 7–30 days in advance with 89–97% accuracy, alerting teams before breakdowns occur and enabling proactive maintenance that reduces unplanned downtime by up to 70 percent, extends asset lifespan by 30 percent, and lowers maintenance costs by 25 percent through anomaly detection, failure pattern recognition, maintenance optimization, and cost forecasting.
⚙️ Production-Based Preventive Maintenance
Maintenance is scheduled based on actual equipment usage, production cycles, and operating hours rather than arbitrary time intervals, using runtime-based triggers, usage-based scheduling, load-dependent intervals, and smart preventive maintenance optimization to reduce unnecessary PM by up to 40 percent, achieve over 95 percent PM compliance, and optimize maintenance windows.
📊 Real-Time Equipment Monitoring
IoT sensors and system integrations provide real-time visibility into equipment health, performance, and operating conditions across the entire plant, supporting multiple IoT protocols, processing over 10,000 messages per second, delivering live dashboards, automated alerts, and performance analytics that enable instant equipment visibility, early issue detection, and OEE optimization to 89 percent or higher.
📦 Spare Parts & Inventory Management
AI-powered demand forecasting keeps critical spare parts available while minimizing excess inventory by using automatic reorder triggers, optimized stock levels, multi-location tracking, and vendor integrations to reduce inventory costs by up to 45 percent, maintain over 95 percent parts availability, and eliminate costly emergency orders.
📱 Mobile Work Order Management
Native iOS and Android applications give technicians full work order management on the go with offline functionality, photo and video attachments, digital checklists, and real-time updates that accelerate work completion by 40 percent, achieve an 87 percent first-time fix rate, and enable fully paperless maintenance operations.
📈 OEE Tracking & Performance Analytics
Automatic Overall Equipment Effectiveness calculation and tracking identifies losses in availability, performance, and quality through real-time OEE measurement, downtime categorization, performance tracking, quality loss analysis, and Six Big Losses reporting to drive data-driven improvements, enable benchmarking, and help achieve an average OEE of 89 percent.
Real Results from Manufacturing Facilities
See how our solutions improve performance, costs, and efficiency
OEE Achievement
Up from 72% average
Downtime Reduction
Reduced from 200 hrs → 64 hrs/year
Maintenance Cost Reduction
$400K+ saved/year
Asset Lifespan Extension
Delayed equipment replacement
PM Compliance
Up from 65%
First-Time Fix Rate
Up from 62%
Mean Time to Repair
Down from 48 hours
Work Order Backlog
Down from 250 orders
Based on 2024 customer survey of 250+ companies
How Manufacturing Facilities Use FacilityFlow
~> Automotive Manufacturing
TITLE: Automotive Parts Production
COMPANY SIZE: 500+ employees, 3 plants
CHALLENGE: Unplanned downtime on injection molding machines was costing $180K per incident. PM compliance was 62%, causing frequent failures.
SOLUTION:
- AI predictive maintenance for 150+ critical machines
- Production-based PM scheduling
- Real-time monitoring of machine health
- Spare parts optimization
RESULTS:
- ✅ 72% reduction in unplanned downtime
- ✅ OEE improved from 71% to 88%
- ✅ $1.2M annual savings
- ✅ 96% PM compliance achieved
QUOTE:"FacilityFlow's AI predicted our compressor failure 2 weeks before it would have shut down our line. That single alert saved us $140K." ~Rajesh Kumar, Plant Operations Director
~> Food & Beverage Production
TITLE: Food Processing & Packaging
COMPANY SIZE: 300 employees, 2 facilities
CHALLENGE: Compliance with FDA and food safety regulations was manual and error-prone. Equipment cleaning validation was on paper checklists.
SOLUTION:
- Digital compliance checklists
- Equipment cleaning validation
- Temperature monitoring integration
- Automated compliance reporting
RESULTS:
- ✅ 100% FDA audit compliance
- ✅ Zero food safety incidents
- ✅ 50% faster cleaning validation
- ✅ Automated compliance documentation
QUOTE:"FDA audits used to take weeks of preparation. Now we pull up our compliance dashboard and we're done in hours." ~ Maria Rodriguez, QA Manager
~> Electronics Manufacturing
TITLE: Electronics Assembly & Testing
COMPANY SIZE: 1,200 employees
CHALLENGE: High-mix, low-volume production required frequent equipment changeovers. No visibility into equipment availability or performance.
SOLUTION:
- Real-time equipment status dashboard
- Changeover time tracking
- Performance analytics
- Resource scheduling
RESULTS:
- ✅ 35% reduction in changeover time
- ✅ 92% equipment availability
- ✅ OEE improved to 85%
- ✅ Better production planning
QUOTE: "Real-time visibility transformed our production scheduling. We know exactly when each line is available." ~ Tom Chen, Production Manager
~> Pharmaceutical Manufacturing
TITLE: Pharmaceutical Production (GMP)
COMPANY SIZE: 800 employees
CHALLENGE: GMP compliance required extensive equipment qualification and validation documentation. Manual processes were time-consuming.
SOLUTION:
- Equipment qualification tracking
- Validation protocol management
- Deviation management
- Audit trail documentation
RESULTS:
- ✅ 100% GMP compliance
- ✅ Zero regulatory findings
- ✅ 60% faster qualification process
- ✅ Complete audit trail
QUOTE: "Our last regulatory inspection was the smoothest ever. Complete documentation instantly available." ~ Dr. Sarah Williams, Compliance Director
Why Manufacturing Facilities Choose FacilityFlow
Purpose-Built for Manufacturing
The platform is built specifically for manufacturing, with workflows, terminology, and best practices included rather than a generic system adapted for the industry, offering production-based maintenance scheduling, OEE calculation and tracking, manufacturing KPIs and metrics, and industry-specific templates.
Scales with Your Operations
From a single plant to multi-site enterprises, manage 10 or 10,000 assets on the same platform with multi-plant management, centralized or distributed control, unlimited asset tracking, and support for global deployment.
Integrates with Your Systems
Connect with existing ERP, MES, SCADA, and BMS systems through 200+ API endpoints for seamless integration with SAP, Oracle, Microsoft Dynamics, Rockwell, Siemens, and Schneider, enabling real-time data synchronization and bi-directional communication.
Mobile-First for Your Team
Native iOS and Android apps give technicians and operators full CMMS functionality on the plant floor, with offline work capability, photo and video documentation, and barcode or QR scanning.
Compliance Made Easy
Stay compliant with ISO 55001, OSHA, and other industry standards using automated compliance reports, complete audit trails, digital safety management, and regulatory documentation.
Exceptional ROI
Achieve typical payback in 2–4 months with 70% lower costs than IBM Maximo, SAP EAM, or Oracle, thanks to all features included, transparent pricing, fast implementation, and no hidden costs.
Seamlessly Integrates with Your Manufacturing Tech Stack
ERP Systems
Work order synchronization, asset data integration, purchase order automation, financial data exchange, and real-time updates across ERP systems.
Industrial Automation Systems
SCADA integration, PLC data collection, MES connectivity, real-time monitoring, and production data capture for industrial automation systems.
IoT & Sensor Integration
Multi-protocol support, processing over 10,000 messages per second, real-time data processing, alert generation, and historical data storage for IoT and sensor networks.
Building Management Systems (BMS)
HVAC monitoring, energy management, environmental controls, and automated reporting for building management systems.
Proven Technology
AI/ML Prediction Accuracy
TensorFlow & PyTorch
Messages/Second
6 industrial protocols
Uptime SLA
Enterprise-grade AWS
Security Standards
ISO 27001, SOC 2, Bank-level encryption
Manufacturing-Focused Pricing That Delivers ROI
Compare what you were quoted versus what you'll pay for 100 users in manufacturing and see how FacilityFlow delivers all features at a fraction of the cost.
MANUFACTURING FACILITY ROI CALCULATOR
Your Facility:
- 100 employees
- Average downtime: 200 hours/year
- Cost per downtime hour: $75,000
- Current maintenance cost: $1.2M/year
With FaciiltyFlow:
- Downtime reduction (68%): $10.2M saved
- Maintenance cost savings (25%): $300K saved
- Extended asset life (30%): $450K saved
- Inventory optimization (45%): $180K saved
- TOTAL ANNUAL BENEFITS: $11.13M
- FacilityFlow Cost: $36K
NET ANNUAL ROI: $11.094M (30,817%)
Payback Period: 1.2 days
Simple, transparent pricing
All plans include our 14-day free trial. No credit card required.
Professional Plan
Mid-size plants
$300/user/year (save 17%)
Users: 26-100 users
Storage: Unlimited
What's included:
All plans include our 14-day free trial. No credit card required.
Frequently Asked Questions About FacilityFlow for Manufacturing
Ready to Maximize Your Manufacturing Uptime?
Join 150+ manufacturing facilities achieving 89% OEE and 68% downtime reduction with FacilityFlow's AI-powered predictive maintenance. ✅ 30-day free trial • ✅ No credit card required • ✅ Full feature access • ✅ Free implementation support • ✅ Manufacturing-specific setup