Maintenance Management System

Unilever, a global powerhouse in the consumer goods industry, operates multiple large-scale manufacturing facilities across Southeast Asia. These factories run around the clock to produce essential household and personal care products. With thousands of machines and systems in constant operation, the need for effective maintenance management is critical—not only to ensure optimal performance but also to minimize downtime, control costs, and uphold safety standards.

In pursuit of operational excellence, Unilever sought a digital solution that could streamline their entire maintenance ecosystem. MLTech Soft stepped in to design and implement a comprehensive Maintenance Management System (MMS) that has since become a core component of Unilever’s daily operations, supporting over 100 maintenance technicians with efficiency, speed, and actionable insights.

The Challenge: Fragmented Processes and Limited Visibility

Unilever faced several significant challenges in managing their equipment maintenance operations, each of which contributed to inefficiencies and operational risk:

• Lack of real-time visibility: Maintenance teams relied on paper-based systems, making it difficult to track task progress and equipment status across multiple factories.

• Connectivity limitations: Many factory areas had limited or no internet access, preventing staff from logging tasks or accessing data on the go.

• Disjointed inventory and work-order management: Spare part tracking, preventive maintenance schedules, and emergency work orders were managed separately, leading to delays and miscommunication.

• Inconsistent reporting: Without a unified system, aggregating and analyzing maintenance performance data was time-consuming and prone to errors.

The Solution: A Scalable, Offline-Capable Maintenance Platform

To address these challenges, MLTech Soft developed a fully customized Progressive Web Application (PWA) tailored for Unilever’s maintenance workflows. The system was engineered for flexibility, ease of use, and maximum accessibility across devices.

Technicians can now use their smartphones, tablets, or desktops to create and manage work orders, capture task details, upload photos, and access inventory data—all within a unified platform. One of the system’s standout features is its offline capability: even when working in areas with no internet access, users can continue logging tasks and taking photos. Once a connection is restored, all data is automatically synced to the central database without manual intervention.

Built on Microsoft Azure, the system guarantees high availability, robust security, and scalability across Unilever’s multiple sites. Additionally, it is fully integrated with Power BI, enabling managers and executives to visualize key maintenance metrics in real-time—such as task completion rates, equipment downtime, and spare part consumption.

Beyond the technical implementation, MLTech Soft worked closely with Unilever’s operations and IT teams to ensure smooth onboarding, user training, and long-term support. The result is not just a software deployment, but a full-scale digital transformation of maintenance operations.

The Result: 5+ Years of Reliable Performance and Continuous Improvement

Since going live over five years ago, the Maintenance Management System developed by MLTech Soft has become a mission-critical tool for Unilever’s factories. It is currently used by more than 100 maintenance personnel on a daily basis, enabling them to complete tasks more efficiently, access accurate information instantly, and contribute to a proactive maintenance culture.

The system has significantly improved preventive maintenance planning, helping Unilever reduce equipment downtime and avoid costly unplanned repairs. With real-time dashboards powered by Power BI, management now has complete visibility into maintenance performance across all sites, allowing for faster and more informed decision-making.

The digitization of work orders and inventory control has also enhanced operational transparency and reduced waste. Maintenance staff no longer rely on paper logs, which has improved data accuracy and accountability.

By combining offline functionality, intuitive design, cloud scalability, and advanced analytics, the solution delivered by MLTech Soft continues to support Unilever’s goals of operational excellence and sustainable manufacturing.