Operational Walkthrough

Polytron

Electronics Manufacturing

Semarang, Central Java, Indonesia

Plants Unified

Assets Tracked

100+

Production Lines

Part Categories

Indonesia's leading electronics manufacturer — AC, refrigerators, TVs, washing machines, and audio systems. Here's how OpexMX would manage maintenance across their 3 manufacturing plants — from SMT lines to refrigerant charging stations.

Plant 1

Semarang Plant

Kawasan Industri Semarang, Jawa Tengah

Full production — AC, Refrigerator, TV, Washing Machine, Audio

Plant 2

Jakarta Plant

Kawasan Industri Pulogadung, Jakarta Timur

TV & AC assembly, warehouse, QC lab

Plant 3

Surabaya Plant

Kawasan Industri Rungkut, Surabaya

R&D, pilot production, environmental testing

The Challenge

Managing maintenance across 3 geographically separated plants

Tracking 100+ production assets from site level down to individual components

Coordinating maintenance teams with varying skill specializations

Moving from paper/Excel maintenance tracking to a centralized digital system

Ensuring production line uptime in a high-volume consumer electronics environment

How OpexMX Handles It

Asset Hierarchy Management

Full asset hierarchy across all 3 plants — sites, areas, machines, sub-assets, and components — with NFC/QR code tagging for field identification.

Smart Work Order Assignment

Skill-based work order assignment matching technician expertise (refrigeration, electrical, mechanical, SMT) to the right task automatically.

Centralized Parts Inventory

Centralized parts inventory with 11 categories covering compressors, PCBs, motors, sensors, and consumables — with reorder level tracking across all plants.

Preventive Maintenance Scheduling

Scheduled PM programs for critical equipment including SMT lines, refrigerant charging units, and calibration of test equipment.

Root Cause & Problem Tracking

Root cause analysis with structured problem groups (compressor, refrigerant, electrical, motor drive, control system) linked to symptom tracking.

Mobile-First Field Access

Technicians access work orders, update status, and log findings from mobile devices on the production floor.

Production Lines Under Management

Production Line	Plant	Key Equipment	Priority
AC Production	Semarang	Assembly stations, refrigerant charging, leak testing, performance test benches	high
Refrigerator Production	Semarang	Assembly stations, vacuum pumps, foaming machines, performance test chambers	high
TV / Display Production	Semarang & Jakarta	SMT pick-and-place, reflow ovens, wave soldering, AOI inspection	critical
Washing Machine Production	Semarang	Assembly stations, drum balancing, spin test rigs, leak testing	high
Audio / Speaker Production	Semarang	Driver assembly, voice coil winding, crossover soldering, anechoic testing	high
Quality Assurance Lab	Semarang	Thermal cycling, vibration testing, hi-pot safety testing	high
Utilities	Semarang	Central chillers, compressed air, electrical distribution	critical

“

OpexMX has a good master data structure that forces good execution. The system grows with the team as our processes mature, the platform adapts instead of getting in the way.

Maintenance Manager

Manufacturing, Surabaya, Indonesia

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