Client: Port Newark Container Terminal (PNCT), a leading U.S. East Coast terminal.
Scope: 1.65 Million TEU/year terminal, 100+ straddle carriers plus quay cranes and yard equipment in a 24/7 operation.
The Challenge
PNCT was running its operation on an outdated, unsupported legacy system:
- Critical to assigning labor and equipment across vessel, yard, rail and gate.
- Only provided basic availability/reliability, with no real fault history or analytics.
- Preventive maintenance was forecasted manually using hours estimates and spreadsheets.
- A persistent communication gap between maintenance, operations, IT and procurement meant delays, missed PMs, and CapEx decisions based on age rather than real behavior.
If the legacy system failed, PNCT risked losing the coordination layer for its entire fleet.
"If something crashes with this system, we're going to be in a bad way." James Kukucka, VP Engineering & Procurement, PNCT
The Solution: EquipmentOS
PNCT partnered with Opsima to deploy EquipmentOS, a real-time equipment operating system built specifically for critical equipment operations.
- Real-time fleet status for every asset, one shared screen used by maintenance, ops, IT and engineering.
- Instant down/up timestamps, failure categorization and diagnostics for each event.
- KPI generation: availability, reliability, MTBF, response & repair time.
- Live PM forecasting driven by telematics/meter data instead of manual forecasts.
- Mobile workflows: foremen and mechanics see status and changes in real time.
- Self-configuration: PNCT can change statuses, assets, rules, and views without vendor support.
- Integration-ready: designed to plug into PNCT's enterprise asset management system and OEM telematics.
"Having the ability to understand what the equipment's doing 24/7 is very important, and we weren't capturing that before." Calogero "Charlie" Ferlisi, Director of Engineering & Equipment Services, PNCT
Measurable Impact
Status changes went from ~1,000/month to ~14,000/month after EquipmentOS.
- Faster detection and repair: everyone can see when a machine fails and when it's back in service.
- Reduced equipment downtime: foremen see availability live, not via calls and radios.
- Stronger PM compliance: upcoming PMs are visible and shared across ops and maintenance.
- Balanced fleet utilization & deferred CapEx: avoid overworking units and time midlife overhauls correctly.
"Since we've been using this new software, availability is up 5%, reliability close to 15%, and MTBF up about 15 hours on straddles." Calogero "Charlie" Ferlisi
"What comes out of EquipmentOS is live and accurate." Calogero "Charlie" Ferlisi
Why PNCT Chose Opsima
- Domain expertise: understanding of terminals, union environments and heavy equipment, not just generic "asset management."
- Speed & agility: the first version was close to PNCT's vision and evolved rapidly through tight feedback loops.
- True partnership: ongoing sessions with engineering, IT and labor; fast responses; "can-do" mindset.
- Configurability: PNCT can adapt the system as operations, assets and workflows change.
- Platform vision: EquipmentOS is becoming PNCT's hub for fleet management and equipment data, not just a maintenance log.
"You weren't just another big software vendor. You gave us a platform to tie together telematics and other use cases in a modern way." Domenic Sidoti, Head of IT, PNCT
"It wasn't like we had to spend a lot of time educating you on our industry. You came in with a concept already and a can-do attitude." James Kukucka
About PNCT
Port Newark Container Terminal (PNCT) is a major marine terminal in the Port of New York and New Jersey handling over 20% of the container traffic in the gateway. PNCT operates a large mixed fleet of mobile equipment, RTGs, and STS cranes in a complex, 24/7 environment.