Manufacturing maintenance software for Malaysian factories and production plants

Run PM on every press, moulding machine, boiler, air receiver and goods lift, keep DOSH and Suruhanjaya Tenaga dates in front of the plant engineer, and let operators report breakdowns straight from the machine.

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Updated 15 Oct 2026

FieldEx scheduling board on desktop with a technician's inspection checklist open on the mobile app, as used by plant maintenance teams

For Malaysian factories, FieldEx joins a computerised maintenance management system (CMMS) with field service management, so the in-house maintenance team and outside contractors share one record per machine. It runs PM on running hours, cycles or dates, tracks DOSH certificate of fitness dates for boilers, air receivers and lifts, takes breakdown reports from the shop floor and keeps spare parts and costs against each machine.

What FieldEx does for Malaysian plant engineers

A Malaysian plant engineer looks after more than production machines. The boiler and air receivers need a DOSH CF, the electrical installation needs its competent person visits under Suruhanjaya Tenaga rules, and the goods lift needs a monthly service. FieldEx puts all of it on the same records as the presses and moulding machines, so nothing sits in a separate file. Book a demo to see it on your own factory.

Machines, utilities and plant rooms in one register

One record per press, injection moulding machine, CNC, conveyor, boiler, air receiver, compressor, chiller, genset and goods lift, with serial number, specs, photos, warranty and the manual attached.
Lines and machines broken into components, such as a press and its clutch, brake, motor and PLC, each with its own history, in asset management.
Machines grouped by factory, building or line, with statuses such as running, breakdown or under PM.
A QR or barcode sticker on each machine, and a log of every change with the user and the time.

PM on hours, strokes or dates

PM plans that start the job at a set number of running hours, strokes or cycles, a date, or whichever comes first, in preventive maintenance.
Separate checklists and technicians for daily, monthly and yearly PM on the same machine.
PM on a fixed calendar for shutdown weeks, or counted from the last completed job. Fixed calendar dates apply to time-based plans.
Each plan showing its machines with the last and next PM dates, and missed PM rescheduled after a set overdue period.

Breakdowns from the production floor

A QR sticker on each machine that opens a breakdown report without logging in, with photos or video.
Each report becoming a job in the backlog, assigned by skill, shift and leave to the right technician.
A warning when the same machine had a job only recently, so repeat failures come to light.
Response and repair targets counted in the factory's working hours, with a warning before a target is missed.

DOSH and Suruhanjaya Tenaga dates

CF dates for boilers, air receivers and lifting machinery, and competent person visits for the electrical installation, as recurring certifications and inspections with custom frequencies.
Each one shown as due, overdue or done, with reminders by email, in the app or both.
The inspector, the date, the result and remarks, with the CF or inspection report attached.
A dashboard of overdue items and those coming due within 7 days.

On the phone at the line

The FieldEx mobile app in English, Bahasa Malaysia and Chinese, so operators and technicians can each use the language they read best.
The machine's past jobs, its checklist, number fields for readings, watermarked photos and a sign-off on each job.
LOTO steps as tasks in a fixed order, and tasks that must be ticked before the job can be closed.
Check-in and check-out on every task.

The maintenance store

Spare parts in each store and each technician's own stock, with transfers, barcode scanning and approvals.
Reorder and low-stock alerts per store, and a quick check of where a part is held, in spare parts inventory.
Each part used logged against the job and the machine, with its price, manufacturer and warranty period.

Plant reports for management

Reports on machine reliability, maintenance cost, utilisation and age, in reporting and analytics.
Job reports grouped by type, line, machine or month, to show PM against breakdown work.
Reports exported as CSV, Excel or PDF, or emailed to management on a set timetable.
Reports exported as CSV, Excel or PDF, or emailed to plant management on a schedule.

Which factory equipment needs a DOSH certificate of fitness, and how often is it inspected?

Under the Occupational Safety and Health (Plant Requiring Certificate of Fitness) Regulations 2024, P.U.(A) 99/2024, in operation from 1 June 2024, plant requiring a certificate of fitness (CF; for lifting machinery, still often called the PMA) includes steam boilers, pressure vessels such as air receivers, and lifting machinery such as overhead cranes and hoists, as well as lifts. The CF is valid for 15 months from the date of inspection, and the periodical inspection must be done before it expires. At each periodical inspection, steam boilers and pressure vessels must be available for internal inspection, unless a vessel was designed not to be subject to one, and lifting machinery must be available for load testing. The Industrial Safety Division of the Department of Occupational Safety and Health (DOSH) handles design verification and alteration approvals for steam boilers, pressure vessels, lifting machinery, lifts and escalators.

In a typical factory that is a boiler, several air receivers and a handful of cranes, each on its own 15-month clock.

What FieldEx does about it

A CF date per item: each boiler, receiver and crane carries its CF as a recurring certification with a 15-month frequency and DOSH recorded as the authority.
Shutdown planned ahead: a preparation job for cooling, draining and opening the boiler or receiver can be raised before the inspection, with its own checklist.
Approvals kept: design verification and alteration approval letters are attached to the item's record.
One list for the plant engineer: the dashboard shows which CFs are overdue or due within 7 days, by building or machine type.

Does a factory boiler need its own steam boiler engineer, or can a visiting engineer cover it?

It depends on the heating surface, single or combined. Under the Twelfth Schedule of the 2024 CF regulations, a visiting steam boiler engineer grade 1 or 2 can cover boilers over 200 and up to 500 square metres. Above 500 square metres, an engineer must be in charge, as the table below shows.

Heating surface (single or combined)	Person in charge
100 m² or less	Steam boiler operator grade 2
Over 100 to 200 m²	Steam boiler operator grade 1, on each shift
Over 200 to 500 m²	Operator grade 1, plus engineer grade 1 or 2 (can be visiting)
Over 500 to 2,000 m²	Steam boiler engineer grade 1 or 2
Over 2,000 m²	Steam boiler engineer grade 1

Many mid-sized factories fall into that band, which is why visiting engineers are common, and why their visits need to be logged as carefully as in-house work.

What FieldEx does about it

Visits as recurring jobs: the visiting engineer's rounds run on a PM plan, with each visit's checklist and readings recorded.
Outside engineers on the same record: visiting engineers can be set up as users with only the access they need, so their work lands on the boiler's history.
Readings as numbers: pressures, water levels and temperatures are entered as exact values on each visit.
Grade as a skill: boiler operator and engineer grades can be skills, so boiler jobs go only to people holding the right grade.

How often must a competent person visit and inspect a factory's electrical installation?

The Electricity Regulations 1994, as amended up to P.U.(A) 136/2014 and published by Suruhanjaya Tenaga, set a minimum number of inspection visits by the competent person. For an installation up to 600 volts on switchgear of 100 amperes or more, the minimum is one visit a month. For an installation above 600 volts and up to 11,000 volts, it is two visits a month. Suruhanjaya Tenaga's chargeman page (issued 6 March 2026) lists the competencies a chargeman covers, including inspection of main switchboard equipment and motor maintenance.

Twelve or twenty-four visits a year per installation is a lot of paperwork to keep in a file the auditor will ask for.

What FieldEx does about it

Monthly or twice-monthly visits: each installation's competent person visits run as a recurring inspection on the right frequency.
A checklist per visit: switchboard, motor and earthing checks are answered on the phone, with readings as numbers.
Findings into the backlog: a failed answer raises a corrective job for the electrical team straight away.
Visit log for the auditor: completed visits can be filtered by installation and period and exported as PDF.

Who can be the competent person in control of a factory electrical installation?

The Electricity Regulations 1994 list who may be in control by voltage. For an installation not exceeding 600 volts, it can be an Electrical Services Engineer, a Competent Electrical Engineer, an Electrical Supervisor or a resident Competent Electrical Engineer. Where the installation is operated over two or more shifts, the owner needs the specified competent person on each shift. Suruhanjaya Tenaga's chargeman page says candidates must pass theory, practical and oral examinations to be certified.

A three-shift factory therefore needs a competent person rostered on every shift, not one person on day shift only.

What FieldEx does about it

Competencies as skills: chargeman, wireman and electrical engineer grades can be set as skills, and electrical jobs go only to people with the matching skill.
Shift rosters: shift schedules, including overnight shifts, are assigned to people or groups, and assignment checks who is on shift.
Leave respected: approved leave is checked before a job is assigned.
Who did what: every job shows who was assigned, who checked in and when.

How often should press machines be inspected in a Malaysian factory?

DOSH's Guidelines on Safe Use of Press Machines (2015) call for a daily inspection before use, a monthly inspection where the machine poses any danger to the operator, and a yearly inspection of the whole premises. The maintenance and servicing schedule must be drawn up from the manufacturer's operating manual or recognised best practice. International guidance from the UK, HSE's HSG236 (second edition, 2003), sets a thorough examination of a power press and its guards at least every 6 months, or every 12 months where the tools are fenced only by fixed fencing.

The daily check is done by the operator; the monthly and yearly checks need the maintenance team, and all three need a record.

What FieldEx does about it

Three cycles on each press: the daily pre-use check, the monthly inspection and the yearly inspection run as separate recurring inspections.
Manual-based PM: the servicing schedule from the press manufacturer's manual runs as a PM plan, with checklists that can be generated with AI from your existing checklist or procedure.
Operators on the daily check: operators scan the press's QR sticker and answer the daily checklist on the phone.
Monthly items flagged: the dashboard shows which presses have missed their monthly inspection.

When should press clutch, brake and motor parts be overhauled or replaced?

DOSH's press machine guidelines (2015) set long-interval tasks for the main parts. The clutch and brake diaphragm and lining are inspected and repaired every 5 years, and clutch drive parts renewed at 15 years. The main motor is overhauled every 5 years and renewed at 15 years, and the PLC is replaced at 10 to 12 years. International guidance from HSE's HSG236 recommends dismantling a positive key clutch at intervals not exceeding 2 years for presses used regularly for single-stroke work on one shift a day.

Five, ten and fifteen-year tasks are easy to lose when the person who planned them has moved on.

What FieldEx does about it

Components with their own plans: the clutch, brake, main motor and PLC are components under the press, each with its own long-interval plan.
Multi-year cycles: custom frequencies cover the 5-year overhaul, the 10 to 12-year PLC replacement and the 15-year renewal.
Age and lifecycle reports: asset reports show each component's age, so overhauls can be budgeted ahead.
Parts history: each part fitted is logged with its date, price and warranty period, against the component.

What should operators check on a machine before starting work?

DOSH's Machinery Safety Basic e-Guide on hand injury (2025) says that before starting any work or operating any machinery, the operator should fill out a checklist on the safety features, especially guarding, sensors and limit switches, and do a visual inspection. DOSH's press machine guidelines say a daily check must be done every day before operations to catch any sudden malfunction.

The checklist is only useful if a failed item stops the machine and reaches maintenance the same minute.

What FieldEx does about it

A pre-start checklist per machine type: guarding, sensor and limit switch questions are grouped into sections, with reference photos showing what a good guard looks like.
Failed items reach maintenance: a failed answer raises a repair job with its tasks, linked to the machine.
Status updated from the checklist: the checklist can set the machine to breakdown, so supervisors see it is not to be run.
Proof the check was done: each completed checklist records the operator, the date and the answers.

What maintenance data should a factory collect after machine inspections?

DOSH's press machine guidelines (2015) say the data collected from inspections should be organised to show which parts are frequently replaced and the specifics of each machine, making future inspections more efficient. The Machinery Safety Basic e-Guide adds that unsafe conditions should be reported to a superior with a written report.

That is the start of reliability work: knowing which part on which machine keeps failing.

What FieldEx does about it

Parts by machine: every part used on a job is recorded against the machine, and spare part reports show which parts are replaced most.
Inspection answers kept: each completed inspection keeps its answers, readings and photos, and can be exported for analysis.
Unsafe conditions reported: a failed safety answer can notify the supervisor's group by email or in the app.
Reliability reports: asset reports show reliability and maintenance cost per machine, so problem machines stand out.

Is there a legal duty to maintain factory machinery under OSHA 1994?

Yes. DOSH's press machine guidelines (2015), citing section 15(2) of the Occupational Safety and Health Act 1994, say employers must make sure press machines are properly maintained, have a good system of work, are safe to operate, and that operators are well trained and supervised. Skrine's Lexology guide to Malaysian occupational health and safety law (law stated 30 May 2023) says all machinery and every part of it must be of sound construction and material, free from defect and properly maintained. The 2024 CF regulations require plant needing a CF to be maintained at all times in a safe and good working condition.

"Properly maintained" is judged after an incident by what the records show was done before it.

What FieldEx does about it

A maintenance record for every machine: each PM job, inspection, repair and part is kept on the machine, with dates and the person who did it.
Who ran each machine: operator sign-offs on pre-start checklists show who ran each machine on each day.
Overdue work visible: overdue PM and inspections are counted on the dashboard, so gaps are found before an audit or an incident.
Edits traced: the machine's change history shows who altered its record and when.

What are DOSH's lockout/tagout steps before machine servicing?

DOSH's infographic Langkah-langkah Lockout/Tagout (LOTO) sets out nine steps for isolating or shutting down machines and equipment from their energy sources before any maintenance, upgrade or servicing work. One of them is to test the operating controls to make sure the machine will not run. International practice under the US OSHA standard 29 CFR 1910.147 adds that each energy control procedure should be inspected at least annually.

Nine steps are easy to remember on a poster and easy to skip on a night shift.

What FieldEx does about it

The nine steps as tasks: each LOTO step can be a task in an ordered procedure, so the next one cannot start until the previous one is done.
Try-start recorded: the control test is its own task, confirmed on the phone before the work begins.
Locks off before closing: removing locks and restoring energy can be required tasks before the job can be closed.
A yearly LOTO review: each machine's LOTO procedure gets a recurring yearly inspection, with the reviewer recorded.

How often do goods lifts in a factory need servicing and examination?

The 2024 CF regulations require lifts and escalators to be serviced and adjusted at least once a month, with a comprehensive examination at least once every 3 months. The owner must also have a service agreement with a competent person, and the agreement must run for at least one year.

So a goods lift carries a monthly service, a quarterly examination, a 15-month CF and an annual contract renewal.

What FieldEx does about it

Monthly and quarterly on one plan: a single PM plan runs the monthly service and the quarterly comprehensive examination, each with its own checklist.
The service agreement as a contract: the lift contract has start and end dates and is linked to the lift and its PM plan.
The CF alongside: the lift's CF runs as a 15-month certification on the same record.
Contractor work visible: the lift contractor's visits are recorded as jobs on the lift, so the factory sees each one.

How should a Malaysian plant measure planned maintenance and downtime?

There is no Malaysian benchmark, so international guidance is the usual reference. PNNL's guide on applying key performance indicators for the US Department of Energy (December 2020) sets availability above 90% and the ratio of unplanned to planned downtime below 25%. PNNL's maintenance approaches benchmarks (July 2021) give target ranges of 20-30% reactive, 25-35% preventive and 30-40% predictive maintenance as opportunities for improvement.

Those figures are a direction of travel. The first step is to log every breakdown so the plant knows its own starting point.

What FieldEx does about it

PM and breakdowns counted separately: each job has a type and shows whether a PM plan generated it, so reports split planned from reactive work.
Monthly trend reports: saved reports group jobs by type and month, and are emailed to management on a timetable.
Breakdown time logged: check-in and check-out times show how long each breakdown job took. FieldEx reports total downtime, MTBF and MTTR for every machine.
Status across the plant: the dashboard shows how many machines are running, under PM or in breakdown.

Customer story

Agri Sumber Prestari (ASP), an agricultural manpower and training company under SD Guthrie Agri Bio, with 92 estates running on FieldEx, moved its machine maintenance off logbooks and paper checklists. Its story describes work orders, inspection checklists and SOPs generated automatically, preventive maintenance triggered by usage or time, and live dashboards of job progress and stock levels with low-inventory alerts.

Read the Agri Sumber Prestari story

Magnum moved its operations off paper forms and inventory sheets onto FieldEx. Its story describes work orders, inventory logs and reports generated automatically, reports sent out on the schedule the team sets, live tracking of team activity, stock levels and job progress, and SLA alerts as deadlines approach.

Read the Magnum customer story

FieldEx questions from Malaysian factory maintenance teams

Which manufacturing maintenance software suits a Malaysian factory?

One that runs PM, takes breakdown reports from operators, keeps DOSH and Suruhanjaya Tenaga dates and spares together, with an app the whole floor can read. FieldEx does all of these, in three languages. See our maintenance software guide.

Can PM run on press strokes or machine cycles?

Yes. Meter units include cycles as well as hours, and plans can trigger on the meter, the date or whichever comes first.

Can operators use the app in Bahasa Malaysia or Chinese?

Yes. The mobile app is available in English, Bahasa Malaysia and Chinese.

Can FieldEx track CF dates for our boilers and air receivers?

Yes. Each one carries its CF as a 15-month recurring certification with reminders and the certificate attached.

Can we record the chargeman's monthly visits?

Yes. Each visit runs as a recurring inspection with a checklist and readings, and the completed visits can be exported for an audit.

Can technicians see the history of a machine before they start?

Yes. The app shows the machine's record, past jobs and parts used, and warns when the same machine had a recent job.

Can we see where a spare part is stored?

Yes. Part availability can be checked by store, zone or technician, with reorder and low-stock alerts for each location.

Can PM be fixed to our shutdown dates?

Yes. Fixed calendar schedules can be anchored to a date or weekday, and jobs can be created a set number of days before they are due.

Can management get maintenance reports without asking?

Yes. Saved reports can be emailed on a set timetable as CSV, Excel or PDF.

How soon can our factory start on FieldEx?

Once we know your requirements and your data is ready, FieldEx can be implemented in as little as a week with standard features for small businesses. Larger setups and custom work take longer. There is no setup fee: setup, data upload and training come with the subscription, and FieldEx onboards customers in person in Malaysia as well as online. See FieldEx implementation in Malaysia.

Put every machine's PM, CF dates and breakdowns on one record

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