Three sprawling industrial campuses—smelters, power blocks and material-handling yards—where 350 certified inspectors must check cranes, conveyors, elevators and EOTs every shift. Paper forms, radio calls and scattered spreadsheets had become a bottleneck.
Challenge
Day-to-Day Impact
Paper Checklists
Hand-written forms caused transcription errors and missing data; uploading photos meant separate camera cards and manual merges.
Slow Approvals
Supervisors reviewed stacks of forms at shift end, delaying defect fixes and compliance sign-offs.
Weak Location Traceability
Equipment often moved between bays; without geo-tags, inspectors struggled to locate the right asset quickly.
No Real-Time KPIs
Leadership lacked a live view of inspection backlog, critical findings or overdue assets.
Pillar
Key Components
Offline-Capable Mobile App
Android / iOS, auto-sync when connectivity resumes.
Structured Checklists
Asset-specific templates with mandatory fields, drop-downs and photo evidence.
Instant Photo & Video Capture
Annotate images, highlight defects, auto-embed in the record.
Geo-Tagging & QR Scans
Locate equipment in seconds; prevent wrong-asset inspections.
Role-Based Workflow
Inspector ➜ Supervisor ➜ Reliability Engineer; push notifications at each stage.
Real-Time Dashboards
Due vs. completed, critical findings, MTBF/MTTR trends accessible on web and mobile.
ERP / CMMS Hooks
API push creates corrective work orders in SAP PM automatically.
Phase
Duration
Milestones
Template Design
2 weeks
300+ checklist points converted into digital templates; criticality scoring added.
Pilot & Feedback
3 weeks
40 inspectors on one site; UI/UX tweaks based on real-world use.
Geo-Mapping & QR Tagging
4 weeks
9,500 movable and fixed assets tagged and mapped to bays, floors, and GPS coords.
Full Roll-Out
3 weeks
Training “toolbox talks,” go-live on all three campuses, supervisor dashboards activated.
KPI
Before
After
Improvement
Inspection Accuracy
68 % (incomplete fields, lost photos)
> 93 %
+75 %
Approval Turnaround
24 hrs
< 12 hrs
2× faster
Asset Locate Time
6 min avg.
< 2 min
3× faster
Paper Handling
100 %
0 %
Eliminated
Supervisor Overtime
18 hrs / week
4 hrs / week
-78 %
Metrics gathered over a six-month post-deployment window.
Success Factor
Detail
Inspector-First UX
Big buttons, offline mode, voice-to-text notes—built for gloved hands and noisy bays.
Evidence-Locked Records
Photos, geo-tags and timestamps are tamper-proof, creating an irrefutable audit trail.
Push-Through Approvals
Supervisors approve on their phones; critical defects auto-escalate to Reliability Engineering.
Data Fusion
Integration with CMMS and Power BI means issues move from finding ➜ work order ➜ KPI trend—without re-keying.
“Our inspectors love the app because it feels made for them. Management loves it because problems surface instantly. A win-win.”
— Senior Manager, Plant Maintenance
Digisailor’s mobile Equipment-Inspection App replaced paper clutter with a seamless, evidence-rich workflow—boosting accuracy by 75 %, doubling approval speed and giving leadership real-time insight into asset health.
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