Unplanned equipment downtime
Critical machines stop without warning, batches are held and the plant loses production hours it never recovers.
Intelligent Asset Management System
Maximize equipment reliability, reduce downtime, automate preventive maintenance and extend asset life with a centralized Asset Management System designed for regulated manufacturing and enterprise operations.
- Preventive maintenance
- Work orders
- Calibration control
- Asset analytics
Asset Management · live
Plant reliability cockpit
Assets tracked
1,482
Open work orders
26
PM due this week
41
Calibrations due
12
Equipment health index · last 12 months
PM dueBlender BL-07 · Block AToday
BreakdownCompressor CP-11In repair
CalibrationHPLC-04 · QC Lab7 days
6 sites · Granulation, Compression, Packing, QC Lab, Utilities
Product film
See IntelliAsset in action
Assets, maintenance, spares, visitors and audits — with digital forms and QR codes for quick audits and reports.
Nexgensis · IntelliAsset
Assets fail quietly, production stops loudly
Most plants still manage critical equipment on registers and spreadsheets — until an unplanned stoppage or an audit observation makes the gap expensive.
Manual maintenance tracking
Job cards, registers and spreadsheets keep maintenance history scattered and impossible to audit quickly.
Missed preventive maintenance
PM schedules slip because reminders live in someone's calendar rather than in a controlled system.
Poor asset visibility
Nobody can say with confidence what assets exist, where they are installed and what condition they are in.
Calibration & compliance issues
Overdue calibrations and missing qualification evidence become the observation an auditor writes up.
High maintenance costs
Reactive repairs, emergency spares and overtime inflate cost far beyond a planned maintenance programme.
Traditional asset management versus intelligent asset management
The same equipment fleet, managed by a controlled system instead of memory, registers and reactive repair.
Traditional asset management
- Asset lists maintained separately by each department
- Maintenance planned on paper registers and reminders
- PM triggered only when someone remembers to raise it
- No data foundation for condition-based maintenance
- Job cards chased by phone, email and shop-floor visits
- Performance judged on memory and anecdote
- Calibration and qualification evidence gathered before audits
- History lost when people or paper files move on
Nexgensis intelligent asset management
- Centralised asset repository with one record per equipment
- Digital maintenance planning with an enterprise calendar
- Preventive maintenance automated by date, usage and runtime
- Predictive maintenance readiness from sensor and history data
- Work order management with routing, escalation and sign-off
- Equipment performance analytics with MTBF, MTTR and uptime
- Compliance tracking maintained continuously and inspection-ready
- Complete asset lifecycle visibility from purchase to retirement
From commissioning to retirement
Every stage of the asset's life is governed, documented and reportable — with no paper handovers between engineering, production and quality.
01
Asset Registration
Every asset onboarded with a unique ID, criticality, location and cost centre.
02
Installation & Commissioning
IQ documentation, handover checklists and commissioning evidence captured digitally.
03
Preventive Maintenance
Frequency, runtime and usage-based plans generated and dispatched automatically.
04
Corrective Maintenance
Breakdowns logged, diagnosed and repaired against a controlled work order.
05
Calibration & Validation
Calibration due dates, tolerance checks and requalification governed by the system.
06
Performance Monitoring
Availability, utilisation and reliability trended continuously per asset.
07
Asset History
A permanent, time-stamped record of every job, part and signature on the asset.
08
Retirement / Replacement
Decommissioning, disposal approval and replacement justification with full traceability.
Sixteen products, one asset record
Registry, maintenance, spares, calibration and analytics operate on the same asset master — never on parallel lists.
Planned, corrective and emergency work on one calendar
Maintenance teams plan capacity, dispatch qualified technicians and close jobs with evidence — instead of chasing job cards around the plant.
Preventive Maintenance Planning
Annual PM plan generated per asset with frequency, tasks and skill requirements.
Schedule adherence98%
First-time-fix rate91%
Average job closure1.4 days
Technicians scan the asset tag to open the job, record readings and sign off on mobile — online or offline.
Request to closure, fully traceable
Seven controlled stages with electronic signatures, downtime capture and cost accounting on every work order.
01
Maintenance Request
Operator or engineer raises a request against the asset from web or mobile.
02
Approval
Supervisor reviews scope, priority and cost, then approves electronically.
03
Technician Assignment
Job assigned to a qualified technician with parts and permits attached.
04
Work Execution
Digital checklist executed on the shop floor with readings and photos.
05
Verification
Engineering or QA verifies the work and the return-to-service condition.
06
Completion
Work order closed with downtime, labour, parts and cost captured.
07
Performance Review
Closure quality, TAT and repeat failures reviewed in the reliability meeting.
Every instrument in date, on record
Calibration and qualification status is maintained continuously, so the inspection question is answered from the screen instead of the archive room.
Calibration Scheduling
Due dates generated per instrument with grace periods and lock-out rules.
Instrument Calibration
As-found and as-left readings against traceable standards and tolerances.
Equipment Qualification
DQ, IQ, OQ and PQ protocols and their approval status held on the asset.
Maintenance Verification
Post-maintenance checks confirming the asset is fit to return to GxP use.
Compliance Monitoring
Live view of overdue calibration, expired qualification and open deviations.
Validation Support
Validation-ready documentation packs generated for inspection on demand.
Compliance dashboard
Calibrations in date
99.1%
Overdue instruments
3
Qualified equipment
412
Requalification due
9
Live alerts
Calibration due in 7 days
HPLC-04 · Quality Control Lab
Qualification valid
Autoclave AT-02 · PQ approved
PM overdue
Compressor CP-11 · 3 days
Work order verified
WO-2291 · Blender BL-07
Reliability measured, not estimated
MTBF, MTTR, downtime and cost trended per asset, line and site — so engineering decisions are backed by the maintenance record itself.
Maintenance KPI performance
Availability96%
PM compliance98%
Utilisation84%
First-time fix91%
Cost vs budget78%
Downtime by cause · last quarter
Mechanical failure34%
Electrical fault22%
Changeover overrun18%
Spare unavailability14%
Utility interruption12%
Equipment Health
Composite health index per asset from failures, PM adherence and condition data.
Asset Availability
Uptime versus planned production time by line, area and plant.
MTBF
Mean time between failure trended per asset class and manufacturer.
MTTR
Mean time to repair broken down by response, diagnosis and repair time.
Maintenance Cost
Labour, spares and contractor cost per asset against budget.
Downtime Analysis
Downtime by cause, shift and equipment with Pareto ranking.
Asset Utilisation
Actual running hours versus capacity across the equipment fleet.
Maintenance KPIs
PM compliance, schedule adherence, backlog and first-time-fix rate.
Connected to the systems that run your plant
Asset Management sits inside OPS IQ and speaks natively to quality, laboratory and manufacturing systems as well as ERP, SAP, SCADA and MES.
Nexgensis Asset Management · OPS IQ
One asset master, one audit trail, twelve connection points — no duplicate equipment lists across departments or sites.
eQMS
Breakdowns and repeat failures raised as deviations, CAPA and change control.
DMS
SOPs, manuals and maintenance procedures served at the point of work.
eBMR
Equipment status and cleaning validity checked before batch execution.
LIMS
Instrument calibration status linked to the results it produces.
ERP
Asset master, cost centres, purchase orders and depreciation.
SAP
Spare parts inventory, procurement and maintenance cost postings.
SCADA
Runtime hours, alarms and condition signals feeding usage-based PM.
PLC
Machine states and counters read directly for trigger-based maintenance.
MES
Production schedules aligned with maintenance windows and downtime.
Barcode / QR Code
Scan an asset tag to open its record, history and open work orders.
Mobile Application
Offline-capable execution of checklists and work orders in the field.
REST APIs
Documented APIs for IoT platforms, BI tools and custom systems.
Equipment records that survive inspection
Maintenance, calibration and qualification evidence is generated as a by-product of the work — attributable, contemporaneous and permanently retrievable.
FDA 21 CFR Part 11
Electronic records and signatures with secure, attributable audit trails.
EU GMP Annex 11
Computerised system controls, risk management and periodic review.
GAMP 5
Category-based, risk-driven validation with a complete deliverable set.
WHO GMP
Equipment maintenance and calibration expectations built into the workflows.
Schedule M
Revised Schedule M equipment records, logs and maintenance evidence.
ISO 55001
Asset management system structure aligned to the ISO 55001 framework.
ALCOA+
Attributable, legible, contemporaneous, original and accurate records.
Electronic Signatures
Meaning-bound signatures with reason, credentials and timestamp.
Audit Trails
Every create, edit and approval captured and reviewable, never editable.
Data Integrity
Role-based access, versioning and controlled data flows end to end.
Measurable gains in uptime and cost
Typical outcomes reported by manufacturers within the first year of running Nexgensis Asset Management.
0%
Less equipment downtime
0%
PM schedule compliance
0%
Lower maintenance cost
0%
Audit-ready asset history
Reduced equipment downtime
Failures prevented rather than fixed, protecting the production plan.
Higher asset availability
More productive hours from the same equipment fleet.
Improved maintenance efficiency
Planned work, right parts, right technician, first time.
Better equipment reliability
Recurring failure modes identified and engineered out.
Reduced maintenance costs
Emergency repairs and overtime replaced by planned intervention.
Increased asset life
Assets maintained to specification last measurably longer.
Improved compliance
Calibration, qualification and history always inspection-ready.
Faster work order completion
Digital routing removes the waiting between every step.
Built for asset-intensive operations
Pharmaceuticals
Biotechnology
Medical Devices
Food & Beverage
Chemicals
Manufacturing
FMCG
Life Sciences
An asset platform, not a maintenance tracker
Asset Management is part of the OPS IQ Platform, so equipment status, quality events and batch execution share one governed data model.
Unified OPS IQ platform
Assets share the same data model as eQMS, LIMS, eBMR and DMS.
Intelligent maintenance planning
Plans driven by usage, criticality and failure history, not habit.
Enterprise asset visibility
Every asset across every site in one searchable registry.
Compliance by design
Part 11, Annex 11 and ALCOA+ controls built into every transaction.
Multi-site deployment
Corporate standards with site-level configuration and reporting.
Cloud or on-premise
Validated cloud hosting or deployment inside your own data centre.
Mobile workforce support
Technicians execute and sign work on the shop floor, even offline.
Scalable enterprise architecture
From one plant to a global network without redesigning the system.
Live in 10 to 12 weeks
A validated single-site rollout including asset master migration, integrations and technician training.
Week 1–2
Discovery
Asset hierarchy, criticality model, maintenance strategy and integration scope.
Week 3–4
Configuration
Registry structure, PM plans, checklists, work order routing and roles.
Week 5–7
Data & Integration
Asset master migration, ERP/SAP and SCADA connectors, barcode tagging.
Week 8–10
Validation
IQ, OQ and PQ execution with the GAMP 5 documentation package.
Week 11–12
Go-live
Technician training, mobile rollout, hypercare and performance baselining.
Asset management questions, answered
An Asset Management System is the single source of truth for every production asset — equipment, instruments, utilities and facilities. It holds the asset registry, plans and executes maintenance and calibration, manages work orders and spare parts, and keeps a complete, audit-ready history of the asset from commissioning through to retirement.
Maximize asset performance. Minimize downtime.
Transform equipment maintenance and asset management with the Nexgensis Asset Management System to improve reliability, reduce operational costs and ensure complete compliance across your manufacturing facilities.
- 45-minute working session on your own asset and maintenance data
- Live walkthrough of PM automation, work orders and calibration control
- Integration, validation and deployment review