Wartungen von technisch komplexen Anlagen

Why the maintenance of technically complex plants poses special challenges

The number of software providers for digital deployment planning and route optimization is now unmanageable. They all pursue the same goal: to relieve maintenance and service companies of the burden of scheduling and to optimize service processing by digitally integrating technicians in order to process maintenance and repairs digitally. For the broad mass of customers such as. This is usually sufficient for HVAC companies.

But what about companies that offer services for technically more complex, mostly stationary plants? There are particular challenges in these areas, which in turn lead to additional requirements for "ideal service software". In this article, you will find out what these are and how they can be mapped in suitable software.

For which companies is simple resource planning not enough?

Compared to simple craft businesses, most deployment planning solutions often reach their limits when they have to meet the requirements of service providers from industry. These include companies from the renewable energy sector such as wind power, biomass and CHP plants. But emergency power and cooling units as well as industrial systems are also among such complex structures and require more than just an overloaded route optimization and a paperless service report. Checklists and forms are essential for maintenance work to document the work on site.

What special challenges do these maintenance companies face?

As described in the introduction, the focus of most software providers is on scheduling and route planning. However, service providers who maintain and service complex plants need many more functions for managing, documenting and evaluating the plants and properties they manage.

Comprehensive system documentation

Where other solutions might only require the serial no. and few data fields, maintenance software for Plant service providers must offer significantly more extensive management options. This includes completely flexible and freely definable data fields to describe the Plant. It must also be possible to maintain the components in any number of hierarchical sub-levels. It must also be possible to define free input fields for each sub-component.

The integration of a file system (images, documents) is also inevitably necessary in order to be able to map the large volume of data. It is not enough to be able to store these in a single place in the object. Instead, it should be possible to store type plates and technical documentation for each component.

Finally, the centerpiece, the plant and service history, should be able to document all events and activities carried out on the plant in a clear and comprehensive manner. Important at this point are the running counter values (operating hours, starts, kilometers, etc.), which can be stored alongside the completed logs and maintenance schedules for each entry. A ticket system for tracking outstanding work and a warranty tracking system are also essential.

Maintenance planning based on meter values (e.g. operating hours)

Instead of simple annual maintenance, the majority of technical plants are serviced according to individual meter intervals such as operating hours. A maintenance plan could, for example be structured as follows:

Maintenance schedule by operating hours (extract)
Maintenance work | Intervals Every 2,000 Bh Every 10,000 Bh Every 60,000 Bh
Record operating data X X X
Check screw connections X X X
Carry out a leak test X X X
Replace coolant X X
Replace turbocharger X X
Major overhaul X

It is not enough to simply issue maintenance reminders according to the above intervals. It should also be noted that in the example above, the larger intervals replace the smaller ones. If the Plant has reached 60,000 operating hours, the maintenance software should take into account that only the W3 interval is carried out and no reminders are issued for W1 and W2.

At the same time, both the system-specific degree of utilization and the operating hours recorded by the technician during the last operation must be included in the maintenance algorithm. Exact maintenance dates can only be predicted if as many parameters as possible are taken into account.

Connection of live machine data

In the age of digitalization, more and more plants are connected to the Internet. This opens up promising opportunities for service providers in particular to optimize maintenance and service.

Good maintenance software should have interfaces as standard in order to be able to integrate live retrieval of machine data. These include the permanent retrieval of meter values. One example is the continuous recording of operating hours for a Plant in order to be able to predict maintenance even more accurately. Error codes such as system downtimes can also be transmitted.

Especially in cases where maintenance contracts have been agreed with the customer, fast response times are extremely important for troubleshooting. The live call can be used to react even faster to unforeseeable failures and, if necessary, a technician can be assigned directly to rectify the fault on site.

Evaluation of the plant fleet

The centralized system management with meter values and special maintenance planning also enables extensive evaluation options. As the service software takes the utilization levels and maintenance intervals of each Plant into account, the following evaluations are possible, among others:

  • How many maintenance services of type W2-20,000 operating hours are expected to be due in the next year?
  • Which Plants are about to undergo a major overhaul and could receive a quote from the sales department?
  • Which Plants are inactive and have not been serviced in the last 6 months, for example?

In addition, it should be possible to export all master and analysis data from the Plant to Excel lists, for example, as required. This is the only way to make fundamental strategic decisions regarding capacity and utilization planning.

Are you a service provider looking for the right software?
Please contact us.


In conclusion, service providers for more complex Plants should set different priorities for their maintenance and deployment planning. The focus is on optimum documentation of the property or Plant. Nevertheless, intuitive deployment planning and mobile order processing are of course still necessary in order to optimize the entire service process. It is worth exploring the market extensively and testing suitable solutions intensively.

If you have any questions about our ADASMA software, which fully covers all of the above requirements, please do not hesitate to contact us.