The Dayton plant from above at the start of first shift: the compressor room, the storeroom, four copper stamping presses with QR tags, the powder-coat cure oven, the loading dock with a forklift and the time-clock entrance, joined by blue aisle routes.

Ready for first shift.

Gasket turns operator requests, PM schedules and sensor readings into work with parts and people, keeps technicians working offline, and spots failing machines before breakdown.

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Press 3 · 400-ton · QR fault
from Luis Ramirez 6:12 am · die clamp leaking → work 4480
Compressor room
no signal → Keisha Johnson's checklist saved offline, synced 7:41 am ✓
Cure oven
392 °F from OPC UA · within limits
Forklift FL-07
Samsara 4,012 engine hrs → 250-hr PM generated
Storeroom
AW-46 hydraulic oil below 4 drums → PO 1187 drafted, $2,756.00
October
PM on time 96% · 3 requests awaiting triage

AC-02 · Oct 13 – 26

From first warning to first shift.

Two weeks, one failing bearing, no breakdown. Every stop below is a record you can open.

1
Tue Oct 13 · 2:40 am
Flagged
AC-02 outboard bearing 0.31 in/s, rising 9 days
2
Fri Oct 16 · 4:05 pm
Staged
Sat Oct 24 shutdown, 6:00–11:30 am · Marcus Bell · 3.5 hrs
3
Mon Oct 19 · 7:10 am
Approved
Work order 4471Dayton has 0 bearings
4
Mon Oct 19 · 2:20 pm
Shipped
Transfer T-0318 · 2 × 6316-C3 from Mesa
5
Tue Oct 20 · 7:41 am
Confirmed
Keisha Johnson’s handheld reading 0.37 in/s, still rising
6
Wed Oct 21 · 10:05 am
Received
bin D-07 · reserved to 4471 ✓
7
Sat Oct 24 · 6:00–10:50 am
Changed
0.08 in/s after restart
Mon Oct 26 · 6:00 am
First shift
Presses 1–4 running · approved 6:40 am by Dana Ortiz

Unplanned downtime on AC-02: 0 min

Charged to AC-02: $580.60 ✓

Detect · Tue Oct 13, 2:40 am

Flagged two weeks before the alarm.

The reliability agent reads AC-02’s live vibration beside its repair history and says why it thinks the bearing is going.

AC-02 · outboard bearing velocity

Oct 4 – Oct 13

0.12 in/s0.31 in/s+158%Alarm 0.45 in/sNo data · gateway restart

Coverage 98.6%
Bearing temp 168 °F, up 14 °F
Source: OPC UA gateway · read-only

Developing bearing wear

AC-02 · 75 hp rotary screw

From the imported history

AC-02 · Mon Mar 18, 2024 · seized at 0.52 in/s, 23 days after the rise · 31 hrs down · $9,840.00
AC-03 (Mesa) · Tue Jun 10, 2025 · failed at 0.49 in/s, 26 days in

Likely to cross 0.45 in/s between Tue Oct 27 and Fri Oct 30

Other cause: loose base or misalignment, less likely · 1× running-speed level unchanged

Proposal: replace both motor bearings at the next planned stop

Accountable lead: Ray Kowalski

Stage · Fri Oct 16 – Mon Oct 19

Staged around Saturday’s shutdown.

The agent fits the repair into production’s planned shutdown, with parts, person, procedure and tool, and folds in the service due anyway.

Staged plan · AC-02 motor bearings

Window: Dayton production calendar (Outlook) · Sat Oct 24 · planned shutdown 6:00–11:30 am · published Fri Oct 16, 3:30 pm
Person: Marcus Bell · millwright · bearing and laser-alignment qualified ✓ · 6:00–9:00 am, restart 10:20 am after 4472 (3.5 hrs)
Parts · BOM rev C: 6316-C3 bearing × 2Dayton 0 · Mesa 3
Polyrex EM grease × 2Dayton 9 ✓
Coupling insert × 1Dayton 2 ✓
Procedure: AC-02 bearing replacement rev 3 + lockout LOTO-AC-02 rev 4 · OEM manual §7.4 attached
Tool: Laser alignment kit reserved Sat 6:00–10:00 am
Pull forward: 2,000-hour service · due at 18,000 hrs · meter 17,842 hrs → same window, Keisha Johnson, 4.25 hrs · one stop instead of two

Sat Oct 24 · 6:00–11:30 am

4471Marcusrestart4472Keishaopen

Approved by Ellen Brandt · Mon Oct 19, 7:10 am→ work 4471 and 4472 created · transfer requested

Parts · Mon Oct 19 – Wed Oct 21

No bearings in Dayton.
Two from Mesa by Wednesday.

The supplier couldn’t make Saturday. Mesa had three on the shelf.

Dayton, OH · EDT

Bin D-07 · 6316-C3

0 on hand

last 2 issued to AC-01, work 4317, Thu Aug 27 · minimum was 0 (imported)

Stillwater Bearing & Transmission · 12 days → Sat Oct 31 · misses the window

Transfer T-0318 · 2 × 6316-C3 · 2-day air · in transit

Mesa, AZ · MST

Bin B-14 · 6316-C3

3 on hand

0 reserved

After T-0318: 1 on hand · PO 1186 restocks Mesa

7:12 am EDT
Agent requests the transfer
11:20 am MST (2:20 pm EDT)
Angela Ruiz dispatches · Mesa left with 1
3:05 pm EDT
PO 1186 · Salt River Bearing Co. · 2 × $151.20 = $302.40 to restock Mesa · drafted by the agent, submitted by Sam Okafor, approved by Ellen Brandt
3:20 pm EDT
Dayton minimum 0 → 2 · approved by Ray Kowalski
Wed Oct 21, 10:05 am
Brenda Walsh receives 2 of 2 into bin D-07 · reserved to 4471 ✓

Saturday’s plan unchanged

The Mesa storeroom in clear desert daylight: the roll-up door open onto a gravel yard with a saguaro and the Superstition Mountains beyond, copper racks with bin B-14 holding one boxed bearing, and Angela Ruiz taping one small box at a steel counter.

Mesa · Mon Oct 19 · 11:20 am MST · T-0318 · 2 × 6316-C3 to Dayton

Generated Mon Oct 19, 12:05 am · 14 work orders · 0 duplicates

Scheduler restarted 12:07 am · resumed

Calendar 9
Meter 3
Route 2
Dayton 9
Mesa 5

Work order	Task	Trigger	Due
4457	Press 2 · monthly clutch and brake inspection	calendar	Mon
4462	Press 4 · die-set check at 1,500,000 strokes	meter
4463	Compressor room · weekly round (AC-01, AC-02, DR-01, RT-01)	route	Tue
4466	Press 1 · weekly lube and air check	calendar	Wed 10:00 am
4468	FL-07 forklift · 250-hr service	meter · Samsara 4,012 engine hrs (last at 3,762)
4464	FL-12 (Mesa) · 250-hr service	meter · Samsara

+ 8 more

Notices held for quiet hours · sent 6:00 am

PM 4466 · Devon Harris

9:30 am · push ‘due 10:00’ · no acknowledgement
12:00 pm · agent asks the blocker · ‘Press 2 die change, free at 2’
2:00 pm · 4 hrs overdue · escalated to Ray Kowalski, blocker attached
2:15 pm · done ✓ · Late 4 h 15 m · kept on the record

PM · Mon Oct 19, 12:05 am – Wed Oct 21, 2:15 pm

Fourteen PMs by morning. One chased to done.

Calendar, meter and route schedules make their own work overnight. When one runs late, it gets chased until it’s done.

Floor · Tue Oct 20, 6:12 – 7:41 am

A scan at the press. A round with no signal.

Luis scans Press 3’s tag to report a leak, and Devon has it running 47 minutes later. Keisha’s round saves in a dead zone and syncs when she walks out.

6:59

EnglishEspañol

Press 3 · 400-ton · Line A

Is the line stopped?

NoYes

Die clamp leaking, left side

Submitted 6:12 am · R-2291

Acknowledged6:16
Resolved6:59 am ✓

Work 4480 · urgent

6:16 · Ray Kowalski converts R-2291 to urgent work 4480 for Devon Harris
6:17 · Devon Harris acknowledges

Downtime 6:12–6:59 = 47 min

Fitting seal replaced · 0.250 drum AW-46 issued to 4480

Finding: clamp supply hose chafed at bolster → follow-up work 4481 · Sat Oct 24

7:41

PM 4463 · compressor room round4 of 4 stops

Discharge: 125 psi
Oil temp: 188 °F
Outboard vibration (handheld): 0.37 in/s

27 waiting to sync27 of 27 synced

Parts as of 6:58 am (snapshot)

Synced 7:41 am · 27 of 27 · 0 conflicts ✓ · reading added to 4471

Stores · Tue Oct 20 – Thu Oct 22

Bought before the oil ran out.

Low stock drafts its own purchase order. The oil arrives Thursday, and the bill goes to QuickBooks once it matches the delivery.

AW-46 hydraulic oil
3.750 drums
minimum 4.000 · bin OIL-2
below minimum
Tue 6:46 am · after 0.250 drum to 4480
2
Purchase order
PO 1187
Wolf Creek Lubricants
AW-46 hydraulic oil, 55 gal4 drums × $689.00 = $2,756.00
deliver Thu Oct 22
- Submitted by Sam Okafor 8:30 am
- Approved by Ellen Brandt 8:50 am
- Sent 9:12 am
- Acknowledged 10:30 am
3
Packing slip
Received Thu Oct 22, 1:40 pm
Brenda Walsh · 4 of 4 · bin OIL-2
- AW-46 drum 1 of 4
- AW-46 drum 2 of 4
- AW-46 drum 3 of 4
- AW-46 drum 4 of 4
On hand 7.750
Invoice
Wolf Creek invoice
AW-46 × 4 @ $689.00 $2,756.00 ✓
Total $2,756.00 ✓
read by the agent · lines matched ✓
approved by Sam Okafor 1:58 pm
QuickBooks Online
Bill synced 2:05 pm
Wolf Creek Lubricants$2,756.00
Open
due Sat Nov 21 (net 30)

PO $2,756.00 = Receipt $2,756.00 = Bill $2,756.00

Shutdown · Sat Oct 24, 6:00 am – Mon Oct 26, 6:40 am

Changed Saturday. Ready Monday.

Three jobs in one planned window. Signed Saturday, reviewed before first shift.

Work order 4471

high priority

AC-02 · corrective, from the agent’s proposal

Procedure rev 3

Lockout applied · Marcus Bell · 6:02 am ✓
Both bearings replaced · 6316-C3 × 2
Alignment 0.002 in ✓
Restart 10:20 am, after 4472
Vibration 0.08 in/s at 10:45 am ✓

Parts 2 × $151.20 + 2 × $14.90 + $80.40 =: $412.60
Labor 3.5 hrs × $48.00 =: $168.00
Total: $580.60 · charged to AC-02

old bearing · digest ✓new bearing · digest ✓

Signed by Marcus Bell · Sat Oct 24, 10:50 am

Approved by Dana Ortiz · Mon Oct 26, 6:40 am

Mon Oct 26 · 6:00 am

Presses 1–4 running
AC-01, AC-02 available (0.08 in/s)
Cure oven 392 °F
0 assets down

3 awaiting review → 0 at 6:40 am

Backlog 412 hrs (was 486)

Sat Oct 24 · 6:00–11:30

4471Marcus6:00–9:00

10:20–10:50 restart and check

4472Keisha6:00–10:15

4481Devon6:00–7:40

4472 2,000-hr service at 17,958 hrs · signed 11:05
4481 Press 3 hose

Window closed 11:30 am, on time

Report · Mon Nov 2, 6:00 am

Where October’s downtime went.

The monthly pack lands in Ellen’s inbox. Each number links to its work, and the agent says what to change next.

Hollis Stamping & Coating · October 2026

Dayton and Mesa

PDFCSV

PM on time

96%

420 of 437 · Dayton 291/302 · Mesa 129/135 · late and skipped counted

Unplanned downtime

618 min

Dayton · 14 events · MTTR 44 min

Press 3 MTBF

118 run hrs

472 ÷ 4

Downtime Pareto

Asset	Minutes	Cumulative
Press 3 · 212 min · 4 events		34%
Cure oven conveyor · 148 min · 2		58%
Press 1 · 96 min · 2		74%
FL-07 · 84 min · 1		87%
Others · 78 min · 5		100%

AC-02 · 0 min unplanned · $1,468.60 (4471 $580.60 + 4472 $888.00) · Mar 2024 failure: 31 hrs, $9,840.00

Requests: 3 awaiting triage

Interval change

Regrease AC-01, AC-02, AC-03 every 1,000 hrs, not 2,000.

Two failures at 1,880 and 1,960 hrs after regrease · OEM limit 2,000 hrs kept as a hard limit

Approved by Ray Kowalski · Tue Oct 27 · rollback: previous revision kept

Since the repair

Sat Oct 24 – Sun Nov 1

AC-02 0.08–0.09 in/s · 0 unplanned stops · coverage 99.2%

30-day review Mon Nov 23

Moving in · Fri Sep 11 – Mon Sep 14

Seven years of MaintainX, moved in a weekend.

Every asset, PM and work order since 2019 comes across, which is where the agent found AC-02’s 2024 failure. Also from UpKeep, Fiix, Limble or a spreadsheet.

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# installs rer, then gets and starts Gasket on your computer
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MaintainX import

Reviewed Fri Sep 11 · applied Sat Sep 12

2 sites
1,214 assets
2,316 parts · $187,420.55on hand
147 vendors

1,032 POs
412 PM schedules ·paused until cutover
38,906 work orders ·since 2019, with procedures and comments
61,240 attachments ·digests matched

86 people · 11 phone-only, invited by text3 duplicate asset tags merged

Shadow compare

PM next dates 412 of 412 ✓

Stock value $187,420.55 = $187,420.55 ✓

Cutover Mon Sep 14, 6:00 am

Presses up by six.

100% free and open source. MIT licensed.

Run Gasket →Read the docs

The Dayton plant's employee entrance from the parking lot at 5:56 am under a deep blue pre-dawn sky: lit windows and door, lot lights, and first-shift workers with lunch coolers walking in.

Mon Oct 26 · 6:00 am · Presses 1–4 running ✓