Keep lines running while you inspect.
ThermalSync lets your team inspect equipment under normal load, on your production schedule, and catch developing faults before they turn into unplanned downtime.
- Inspect under normal load
- Repairs in planned stops
- Every line at a glance
- Assets inspected
- 64
- Lines stopped
- 0
- Open exceptions
- 2
Illustration: a live thermal image of Line 3's drive motor and pump, inspected while the line keeps running under normal load.
Inspection shouldn't stop production.
A contractor survey squeezes the whole plant into one day, and anything not running that day gets skipped. Your team inspects each line whenever it runs, under normal load, without stopping a thing.
- Every line under load. Inspect each line while it runs, so every reading counts.
- Rounds that fit your shifts. One asset or a whole line, whenever it suits the crew.
- Repairs in planned stops. Book the fix into a changeover you already have.
- Under load
- 212/212
- Lines missed
- 0
- Lines stopped
- 0
Illustration: a week of production on four lines. A contractor survey on Wednesday's day shift misses Line 2, which is in a changeover and not under load. Your team inspects every line while it runs across the week, covering all 212 assets without stopping a line. A round on Tuesday flags an exception on Line 3, and the repair is booked into Sunday's planned stop.
Catch it early. Fix it on your schedule.
A failing connection or bearing usually runs hot well before it breaks. Regular rounds catch that heat while there’s still time to plan the repair.
- Found by
- Tuesday’s round
- Fixed in
- Sunday’s planned stop
- Unplanned downtime
- None
Illustration: equipment condition over time. A connection starts to degrade; a regular thermal round finds the heat early, the repair happens in a planned stop, and the equipment is back to normal. Without inspection, the same fault goes on to audible noise, a hot enclosure, and a breakdown with unplanned downtime. The time between finding the heat and the breakdown is your planning window.
From the floor to the fix.
Follow one finding. Images sort themselves, the exception reaches maintenance as a work order, and the next round proves the repair worked.
- Image to work order
- 40 min
- Line stopped
- 0 min
Example timeline from a single round.
-
Tue 06:40
Captured on the morning round
+ 36 images · line running -
Tue 07:05
Uploaded and sorted automatically
IR_0412.jpg MCC-3 › Bucket 4B
-
Tue 07:06
Exception flagged
Severe Phase B line side · 189.2°F · ΔT +41°F
-
Tue 07:20
Work order in your CMMS
WO-1042 · CMMS Re-torque Phase B lug, MCC-3 2 -
Sun 22:00
Fixed in the planned stop
Lug re-torqued during Line 3’s changeover. No extra downtime.
-
Mon 06:45
Verified on the next round
Resolved Phase B · 148.3°F
The whole plant, one view.
Coverage, overdue assets, and open exceptions for every line, updated as your team inspects. No spreadsheets, and no chasing anyone for status.
- Program health by line and area
- Overdue and due-soon assets, before they slip
- Audit-ready Inspection Reports for NFPA 70B
- Open exceptions
- 2
- Overdue
- 2
- Due this week
- 6
- Line 1 58 assets All clear
- Line 2 38 assets 6 due this week
- Line 3 72 assets 1 resolved
- Packaging 44 assets All clear
- Compressor room 12 assets 1 exception
- Main switchgear 18 assets 1 exception
Illustration: program health for Plant 2, Riverside. 96.7 percent of 242 assets inspected this quarter, 2 open exceptions in the compressor room and main switchgear, 2 overdue assets, and 6 assets on Line 2 due this week.
Why plant managers choose ThermalSync
Inspect without shutdowns
Capture thermal images under normal operating conditions. No production windows to negotiate and no lines to stop.
Catch faults before downtime
Temperature trends across inspections show the slow drift toward failure, so repairs happen on your schedule, not the equipment's.
Know what needs attention
Assisted fault finding flags exceptions in the context of each component, so your team reviews what matters first.
Findings become work orders
Send exceptions to your CMMS as work orders with the thermal images attached. Close the loop without re-keying anything.
Ready for NFPA 70B
Audit-ready Inspection Reports and a complete record for insurers and auditors, generated from the work your team already did.
Every line at a glance
Program health, overdue assets, and open exceptions for the whole plant in one view.
Do inspections interrupt production?
No. Thermal images need equipment running under normal load, so your team inspects while lines run. There’s no need to plan every asset into a single day: inspect one asset or a whole line whenever it’s running.
Who performs the inspections?
Your own electricians and maintenance technicians. Once setup is done, any experienced team member can inspect, and assisted fault finding helps surface exceptions. We still recommend thermography training so your team knows what to look for.
Does it work with our CMMS?
Yes. Findings can create work orders in your CMMS with the thermal images attached, and we’re adding deeper integrations with the tools teams already use. Ask us about yours.
How long does setup take?
It depends on your site. Smart Builder generates a baseline of your assets, components, and inspection points during account setup, so nobody has to catalog everything by hand.
Will it help with NFPA 70B and our insurer?
Yes. Custom inspection frequencies, a maintenance program view, audit-ready Inspection Reports, and a complete activity trail keep your records ready for auditors and insurers.
Ready to inspect without stopping the line?
See how ThermalSync fits your production schedule. Book a 30-minute demo built around your equipment.
or email support@thermalsync.com