Predictive maintenance and CMMS for factories

Fix it on Sunday, not at 3 AM on Monday.

Schafte reads your machines' vibration, temperature and run-hours, predicts likely failures days ahead, turns them into planned work orders, runs preventive maintenance, keeps the right spares ready and shows exactly where downtime comes from.

Monitor 5 machines free Watch a bearing get saved
LINE 3 EXTRUDER DRIVE · 14,200 MMM-3 · 75 kWSCHAFTEGB-3 · CRITICAL
VIB-GB3-022.1 mm/s
TMP-GB3-0158 °C
RUN-L318,442 h
WO-1882PLANNED

Replace bearing 6312, GB-3 output side

Sun 06:00 · LOTO checklist · 2 techs

The bearing that didn't failLine 3 Extruder · Gearbox GB-3 · Critical asset

Vibration

2.1mm/s

Temperature

58°C

Status

Normal

Auto componentsSteelCementTextilesFood and beveragePharmaPlasticsPaper millsAuto componentsSteelCementTextilesFood and beveragePharmaPlasticsPaper mills

Inside the machine

One plant. Seven parts. Every one of them talks.

Schafte is laid out the way your machines are. Each part of the drawing is a module, and each module writes to the same asset history, so a vibration alarm, the job that fixed it and the bearing it used sit on one record.

ItemModuleDoes
01Machine RegistryAssets, drawings and history02Sensor WatchVibration, temperature, current03AI Failure PredictorLikely failures, days ahead04Work OrdersBreakdown and planned jobs05PM SchedulerPreventive maintenance plans06Spares CribSpare parts and reorders07Downtime ReportsMTBF, MTTR and cost
The nameplate · MR-01

Machine Registry

Every machine with location, make, drawings, manuals, criticality and full maintenance history, opened by scanning the QR tag on the machine.

  • QR tag on every machine opens its record
  • Drawings, manuals and OEM contacts in one place
  • Criticality A, B, C drives alarm and job priority
Explore Machine Registry
Machine Registry
412 ASSETS
TagAssetAreaCrit
GB-3Gearbox, Line 3 ExtruderBay 4A
M-3Main motor 75 kWBay 4A
CP-12Cooling water pumpUtilityB
AC-02Screw compressor 37 kWUtilityA
CV-07Belt conveyor, packingHall 2C

GB-3

Helical, ratio 12.5:1 · installed 2017

Drawings

6

Manuals

3

History

41

Last overhaul14 Mar 2025

OilISO VG 320, 38 L

Bearings6312, 22216 E

The motor · SW-02

Sensor Watch

Wireless vibration and temperature sensors, plus readings from PLCs and energy meters, with trends, bands and alarms per machine.

  • Wireless vibration and temperature every 10 minutes
  • PLC and energy meter tags over Modbus TCP and OPC UA
  • Alert and trip bands set per machine class
Explore Sensor Watch
Sensor Watch
GB-3 · 21 DAYS

Velocity RMS, output bearing (mm/s)

Alert 4.5Trip 7.1

Vibration

4.6 mm/s

Bearing temp

66 °C

Motor current

118 A

Run-hours

18,442 h

The shaft · AI-03

AI Failure Predictor

Compares each machine's trends with its own history and known failure patterns, then estimates likely failures with a confidence level for engineers to judge.

  • Learns each machine's own baseline
  • Names the likely fault and the evidence behind it
  • Gives a failure window and a confidence level
Explore AI Failure Predictor
AI Failure Predictor
ADVISORY

GB-3 output bearing 6312

Outer-race wear pattern

Confidence: medium-high

Likely failure window from today

Sun9-14 d
0102030 days

Evidence

  • Peak at outer-race defect frequency, 3.2x baseline
  • Bearing temperature up 8 °C over 14 days
  • Trend shape matches 2 past failures on this asset

Engineer decision

Raise work orderWatch 48 h moreDismiss with reason
The drive belt · WO-04

Work Orders

Breakdown and planned jobs on technicians' phones, with checklists, lockout-tagout steps, photos and supervisor sign-off.

  • Raised from a prediction, an alarm or a phone
  • Lockout-tagout steps set by the plant
  • Photos, time and spares booked to the job
Explore Work Orders
Work Orders
WO-1882

Replace bearing 6312, GB-3

In progress

Planned · Sun 06:00 · R. Patil, S. Khan

  • Isolate M-3 at MCC panel 4, lock and tag
  • Verify zero energy, try start at local station
  • Remove coupling guard and drain oil to 20 L mark
  • Pull bearing 6312, fit new, check end-float 0.05-0.10 mm
  • Refill ISO VG 320, remove locks, trial run 30 min

Photos

Spares6312 x1 issued

Time1 h 52 m

Sign-offShift engineer

The timing belt · PM-05

PM Scheduler

Preventive maintenance by calendar, run-hours or measured condition, slotted into planned shutdowns instead of production hours.

  • Calendar, run-hours or condition triggers
  • Jobs grouped into planned shutdowns
  • PM compliance tracked per area
Explore PM Scheduler
PM Scheduler
WEEK 44

Mon

Grease M-3 bearings

Calendar

Tue

Compressor AC-02 filter

Run-hours

Wed

Conveyor belt tension

Calendar

Thu

CP-12 seal check

Condition

Fri

Hydraulic oil sample

Run-hours

Sat

Sun

Shutdown

GB-3 bearing 6312

Condition

Extruder heater bands

Calendar

Calendar Run-hours ConditionPM compliance this month: 94%
The toolbox · SC-06

Spares Crib

Spare parts stock by bin, reservations against planned jobs, minimum levels and reorder alerts before the shelf runs empty.

  • Stock by store and bin
  • Parts reserved against planned jobs
  • Reorder alerts at minimum level
Explore Spares Crib
Spares Crib
STORE 1
PartBinStockMinResvdStatus
6312 C3B-14221 WO-1882OK
22216 EB-1412-Reorder
V-belt SPB 2120C-0364-OK
Mech. seal 45 mmD-0801-Stock out
Contactor 95 AE-0232-OK
Mech. seal 45 mm is below minimum and fits CP-12, a B-critical pump. Purchase request PR-311 drafted.
The control room · DR-07

Downtime Reports

Downtime by machine and reason, MTBF, MTTR and maintenance cost per asset, laid out for the monthly plant review.

  • Downtime by machine and reason
  • MTBF, MTTR and cost per asset
  • Monthly plant review pack, ready to export
Explore Downtime Reports
Downtime Reports
Q3 · PLANT 1

MTBF

212 h

+38% vs Q2

MTTR

2.4 h

-31% vs Q2

Unplanned

105 h

-44% vs Q2

Unplanned downtime by reason (hours)

Bearing failure41
Hydraulic leak26
Electrical trip18
Belt / chain11
Waiting for spares9

The gear train

Every reading turns the next gear.

A rising trend becomes a prediction, the prediction becomes a planned job, the job pulls a reserved spare, and the result feeds the next report. Nobody has to copy anything from one sheet to another.

STEP 1

Read

Sensors and PLCs report vibration, temperature, current and run-hours.

STEP 2

Predict

AI flags a fault pattern and gives a failure window with confidence.

STEP 3

Plan

A work order is slotted into the next planned shutdown.

STEP 4

Fix

Technicians follow the checklist, use the reserved spare and sign off.

STEP 5

Learn

The repair and its result train the model and update MTBF.

Read-only by design

It advises. Your engineers decide.

Schafte has no write path to any PLC, drive or control panel. It listens, it estimates, and it puts the evidence in front of the people responsible for the plant.

Advice with confidence

Every prediction shows its confidence level and the evidence behind it, for an engineer to judge.

Never controls machines

Schafte never starts, stops or changes a machine. Connections to PLCs are read-only.

Plant safety rules

Lockout-tagout and safety checklists are set by the plant and stay the plant's responsibility.

Your data stays yours

Machine data is private to your company, encrypted in transit and at rest, and never sold.

Wiring diagram

Plugs into what is already on the floor.

Start with rented wireless sensors on the machines that hurt most, then add the PLC tags, energy meters and ERP records you already have.

See Sensor Watch

Wireless sensors

Vibration and temperature

PLCs

Modbus TCP, OPC UA

IoT gateways

MQTT

Energy meters

Modbus RTU via gateway

SAP PM and MM

Equipment, orders, spares

Excel and CSV

Asset and spares import

Questions from the shop floor

Asked by maintenance heads

Not always. If your machines already report to a PLC or SCADA, Schafte can read those tags. For motors, gearboxes, pumps and fans without monitoring, we sell or rent wireless vibration and temperature sensors that mount with a magnet or a stud in minutes.

No. Schafte only reads data. The AI Failure Predictor gives advice with a confidence level, and your maintenance engineers decide what to do and when. Nothing in Schafte can start, stop or change the settings of a machine.

Yes. The technician app keeps assigned work orders, checklists and asset records on the phone. Jobs can be updated and photos taken without signal, and everything syncs when the phone reconnects. Sensor gateways buffer up to 7 days of readings during a network outage.

Yes. The technician app is available in English, Hindi and Marathi, with Tamil, Telugu, Kannada and Gujarati also available. Checklists can be written in the language your team works in.

Yes, on the Bull Gear plan. Schafte can sync functional locations, equipment, notifications and work orders with SAP PM, and exchange spares data with SAP MM. A REST API is available for other ERP systems.

Most plants import their asset list from Excel and run their first work orders within a week. Sensors on the first 5 machines take a day to fit. The AI needs about 14 days of readings to learn each machine's baseline before it starts predicting.

INSPECTION TAGNO. 0005

Hang a tag on your first 5 machines.

Machines
5
Days free
60
Card needed
No

Signed: maintenance head, ____________

Control station

  • Start with sensors we rent you, or with PLC data you already have
  • Asset register, work orders and PM live in the first week
  • Your first AI baseline is ready after about 14 days of readings
STARTMonitor 5 machines freeCreate your plant accountContact Us Plan a multi-plant rollout