Manufacturers are stepping up investments in their plant’s IT infrastructure due to an increasingly competitive global market. The business’ goals are demanding more from production and as such the availability and reliability of assets is evermore mission critical (as indicated in ISO 55000).
With a holistic approach to maintenance that involves managing both reliability and risk assessment across an entire organization, the efficiency of each plant can be optimized increasing productivity and ultimately profitability. Without a doubt, the definition of maintenance plans is an important activity in a company with the importance of the plan scaled by two factors: first, the size of the company and the availability of its financial and labor resources and secondly, the company objectives in which maintenance plays a part. One of the key resources in maintenance is the information system and software tool used.
“Smart Asset Manager” (SAM) focuses on manufacturers’ critical needs: standardization, organization of assets and traceability of maintenance activities. Smart Asset Manager is a Web-Based (HTML5) modular software package available on PC workstations, HMI devices and tablets for either for Android or IOS.
Functionally, it is composed of synergic modules cooperating to create a tailored package for individual maintenance needs. All together these modules offer a complete vertical solution for any global manufacturer.
In particular, SAM:
SAM can manage different kinds of maintenance targets: Production Machines, Facilities (buildings, structures, etc.), Auxiliaries (heaters, refrigerators, pipes, etc.).
The maintenance targets are organized in a hierarchical tree view. These assets can be instantiated from a corporate template and fine-tuned for local configurations. Machines are classified depending on their importance in the process and these different categories can follow their own configurable escalation procedure: SAM has implemented in fact an automatic escalation mechanism, through e-mails and SMS/Text to previously identified operators.
SAM can inspect and correct incipient failures either before they occur or before they can turn into major defects. To do this, the maintenance administrators can create a preventive plan template applicable to all machines in the plant belonging to the same machine model. The preventive plan template, consisting of both macro and micro tasks, has attributes like the specific sub-assemblies of the machine to inspect, the tools to be used, and work-instructions. Finally, the maintenance plan is instantiated in Gantt charts where it is possible to schedule all activities. The system guides the operator to follow the correct priority of the maintenance tasks.
Condition-based maintenance is triggered by measurements and events from the shop floor (SCADA), such as measurements of noise, vibrations, temperature, pressure, and machines cycles. According to the values received, SAM calculates the number of times a constraint is violated automatically creating a maintenance task. Maintenance tasks created in this way, are visible in a Gantt chart letting the user schedule them in relation to other activities.
Corrective maintenance is carried out after a failure is detected and aims to restore an asset to a condition in which it can perform its intended functions. The shop floor (SCADA) sends an alarm to SAM which automatically creates a Breakdown Order Request. Depending on the importance of the asset, it is possible to configure an escalation mechanism which sends emails and SMS messages to the people previously identified. The operator, using an interface optimized for tablets, selects the activity to perform, changes the maintenance target if needed and selects the spare parts recording their barcodes. The system will automatically suggest correct spare parts based on previous related maintenance. Using a tablet allows the technician to upload photos of the failure and record audio messages in mp3 format.
Spare parts are booked by the operator. For every selected spare part, the system activates:
Once the operator has chosen the needed spare part, the system is able to automatically send an e-mail to the warehouse operator. Being SAM flexible and highly configurable, the maintenance operator can consume spare parts directly in ERP. The system is able to constantly monitor the usage of spare parts when executing a maintenance task including associated costs, to actualize the stock and to send alarms in case the quantity remaining of a specific spare part reaches a critical threshold.
The maintenance cost is calculated according to maintenance duration and to the usage of spare parts. Interventions are assigned to operators, machines and to a cost center. The operators can be internal or external and work individually or as a group on a case-by-case basis. The cost of the personnel and spare parts used in the intervention can be extracted directly from the ERP.
SAM calculates and presents the most important maintenance KPIs out of the box, like Mean Time Between Failures - MTBF, Achieved Availability - MTBM / (MTBM + MTTR).
Together with these and other KPIs, SAM measures reliability, maintainability, availability, resource effort and cost. Reports are available in Microsoft Reporting Services, Excel and PDF.
Examples of some reports include:
Apr 29, 2016