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Case studies

Real problems, in real plants

TNS and OPTIMUS run on our customers’ production floors and utility areas. Here is the problem each one brought, what we installed, and what changed afterwards.

  • Kereta Api Indonesia
  • Asian Isuzu Casting Center
  • YPTI
  • Armeta Kreasi Mandiri
  • Dharma Group

Where almost every project starts

These four problems show up in nearly every project, whatever the industry or plant size.

01

Utilities stop without warning

  • No signal beforehand
  • Production is disrupted
  • Revenue at risk

02

Energy cost out of control

  • No per-machine measurement
  • Waste has no clear source
  • Operating cost keeps rising

03

Productivity you cannot see

  • No real-time machine performance
  • Bottlenecks are hard to find
  • Decisions run on assumptions

04

Reactive maintenance

  • Fixed after it breaks
  • Short asset life
  • High spare-parts spend

Five deployments in the field

Transportation, metal casting, plastics manufacturing, and precision machining.

PT Kereta Api Indonesia · Transportation · OPTIMUS

Generators no longer stop without warning

Generator condition is watched continuously, so signs of trouble show up before the machine quits.

Kereta Api Indonesia

Problem

  • Generators failed without warning
  • Operations stopped abruptly
  • High downtime cost

What we installed

  • Continuous machine condition monitoring
  • Early alerts when condition changes
  • Recommended preventive actions

What changed

  • Less unplanned downtime
  • More stable operations
  • Lower emergency repair cost

PT Asian Isuzu Casting Center · Metal casting · OPTIMUS

Planned maintenance instead of waiting for breakdowns

Maintenance is scheduled from asset condition, with clear priorities for the team.

Asian Isuzu Casting Center

Problem

  • Reactive maintenance
  • Short machine life
  • Excessive spare-part replacement

What we installed

  • Condition-based maintenance recommendations
  • Planned maintenance schedules
  • Clear action priorities

What changed

  • Longer asset life
  • More efficient maintenance spend
  • More predictable operations
Related capabilitiesAsset Health MonitoringCMMS

PT YPTI · Precision machining · OPTIMUS

Maintenance cost, finally visible per work order

Repair cost and loss avoided are recorded on every work order.

YPTI

Problem

  • Maintenance cost was hard to track
  • Maintenance activity was opaque
  • Effectiveness was hard to evaluate

What we installed

  • Repair cost and loss avoided per work order
  • Central work orders and spare parts
  • ROI and net benefit dashboard per area

What changed

  • Transparent maintenance cost and activity
  • Work orders and completion tracked
  • Team performance visible
Related capabilitiesMaintenance AnalyticsCMMS

PT Armeta Kreasi Mandiri · Manufacturing · TNS

The electricity bill, broken down to the machine

Energy use is visible per machine and area, including abnormal spikes.

Armeta Kreasi Mandiri

Problem

  • High electricity bills
  • No transparency on energy use
  • Unknown sources of waste

What we installed

  • Real-time energy monitoring
  • Consumption per machine and per area
  • Detection of abnormal consumption spikes

What changed

  • Energy cost under control
  • Savings potential clearly visible
  • More efficient operations

PT Dharma Poly Plast · Plastics manufacturing · TNS

OEE calculated automatically, not compiled at month end

Every machine’s status reads off a 3D model, with productivity and downtime.

Dharma Group

Problem

  • No real-time view of productivity
  • OEE calculated by hand, and late
  • Bottlenecks hard to find

What we installed

  • Real-time 3D machine status
  • Visibility of productivity and downtime
  • Transparent production performance

What changed

  • Higher productivity
  • Bottlenecks found quickly
  • Better-targeted improvement decisions

Why there are no percentages on this page

A savings figure only means something when a baseline was measured before the system went in and the customer has agreed to publish it. For the deployments above, that baseline is not yet at a stage we can publish, so the impact is described qualitatively. We do not make numbers up.

What we can show today is the system itself. Every screenshot on the solution pages is taken from TNS and OPTIMUS running, and we can demo it live.

Every project above started small

One line or a few critical assets, with a baseline measured from day one so the result can be verified, not estimated.

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