// THE SCENE
Prakash. Chakan. 8 CNC machines. Bajaj Auto supplier.
Manufacturer says: service every 500 running hours.
Nobody tracks hours. Operator guesses: "6 mahine ho gaye."
Last month: spindle bearing on Machine 3 seized.
4 days downtime. Rs 1.2L repair. Rs 1.6L lost production.
Urgent Bajaj order delayed. Reputation damage: unquantifiable.
All preventable with a calendar and basic arithmetic.
// THE COST
1 breakdown/quarter × Rs 2.8L (repair + downtime + lost orders).
= Rs 11.2L/year in preventable breakdowns.
Rs 11.2L/year. All from skipping a service schedule.
No IoT sensors needed. No Rs 10L investment.
Just someone counting hours. We automate that.
// THE FIX
Operator WhatsApps "M3 started" when machine turns on.
WhatsApps "M3 stopped" when it turns off. That's it.
At 450 hours: "Machine 3 — service due in ~47 running hrs."
At 500 hours: "OVERDUE. Schedule this week."
WhatsApp messages + arithmetic. No sensors. No IoT.
Service scheduled before failure. Every time.
// THE MATH
BEFORE: Guesswork. Bearing seized. Rs 2.8L gone.
AFTER: Service scheduled at 450 hrs. Rs 15K service cost.
Rs 2.8L breakdown avoided → Rs 15K service.
Savings: Rs 11.2L/year across 8 machines.
Cost: Rs 29,999. ROI: 37x. One avoided breakdown pays for it.