Organisations today face dynamically changing priorities and high workloads in their operations. In such a situation, maintenance managers need an effective and reliable tool in order to plan effectively, complete tasks on schedule and make quick, comprehensive reviews when resources available at their disposal are scarce.
CAMM System delivers a high powered solution for the whole gamut of maintenance functions. The application group comprises three modules: Maintenance Administration & Control, Equipment and Maintenance Operations.
In an industry, cost of unscheduled stoppage of an equipment is very high, in terms of loss of production and money. Maintenance is an activity carried out to avoid unscheduled stoppages and breakdowns of the equipment, to improve availability and life of plant and machineries, thereby improving the performance of the industry. The effectiveness of production is highly dependent on quality of maintenance. One of the key factor for the success of an industry is an effective maintenance management system.
Proper maintenance management can improve existing capacity utilization rather than going in for additional capacities to meet the ever increasing demand of a large number of products and services.
Maintenance is only viewed as a repair function, however it is a combination of any actions carried out to retain an item in or restore it to an acceptance condition.
The principal objectives of maintenance activity are:
1. To maximise the availability and reliability of all assets (equipment, machinery)
2. To extend the useful life of assets by minimising wear and tear and deterioration.
3. To ensure operation readiness of all equipments required for emergency use at all times.
4. To ensure the safety of personnel/using facility.
The availability (A) of a plant can be defined as:
A = Tup / Tup + Tdown
Tup = The cumulative time of operation in the normal working state
T down = The cumulative downtime.
Reliability - The probability that a unit will function normally when used according to specified conditions for at least a stated period of time.
Maintainabilty - The probability that a failed unit is put back to satisfactory, operable condition in a given down time.
TYPES OF MAINTENANCE SYSTEM:
An unplanned maintenance, which is necessary to put in hand immediately to avoid serious consequences, for instance loss of production extensive damage to assets or for safety reasons. Emergencies should remain exception rather than the rule. To ensure such a possibility, it is better to have planned maintenance systems.
Maintenance organised and carried out with forethought control and records to a predetermined plan. Planned maintenance can be split up into essentially two main activities, namely preventive and corrective.
Preventive Maintenance: Also termed Predictive Maintenance:
Is carried out at predetermined intervals or to other prescribed criteria and is intended to reduce the likelihood of an equipment’s condition falling below a required level of acceptability. The proverbial saying “ Prevention is better than cure” or “A stick in time saves nine” is basic philosophy of preventive maintenance – done on machines either when running or during shutdown e.g. (1) changing of lube oil after a fixed hours of running (2) changing of bearings after one year of operation.
Maintenance which can be carried out when the system is in service.
Maintenance which can only be carried out when the item is out of service. Further preventive maintenance can be time based or condition based.
Time based Preventive Maintenance:
This policy is effective when the failure of any item of equipment is time dependent.
Condition based Maintenance:
In response to a significant deterioration in unit as indicated by a change in monitored parameter of the unit condition or performance. SIGNATURE ANALYSIS which is intended to continually monitor health of the equipment by recording systematically signature or information derived from the form of mechanical vibrations, noise signals, acoustic and thermal emissions, changes in chemical compositions, smell, pressure, relative displacement and so on.
Maintenance carried out to restore an item which has ceased to meet an acceptable condition – involves minor repairs, that may crop up between inspections.
Total maintenance planning embraces all activities necessary to plan, control and record all work done in connection with keeping an installation to the acceptable standard by devising appropriate maintenance system.
The most important single document in the organisation of maintenance is termed work order/maintenance request. A pre-requisite for planning the maintenance function is necessary to know exactly what the labour force is doing and how long each task takes.
The maintenance request by the production staff details the defect or work believed to be required. The “Cause” should have been identified “before” or “after” rectifying the fault so as to help planners for conducting subsequently studies for critical analysis and all important function of “designing out” maintenance. The maintenance request provides all information necessary as regards the type of labour employed and the time labour has taken to do the job.
In a changing world of competition the survival of industries depends on quick decision making and effective management of maintenance function. To accomplish the above objective presently “Computer Aided Maintenance Management Software Packages” are available for the maintenance managers.
CAMM System is a reliable tool available to plan effectively complete tasks on schedule and make quick reviews. This can also be treated as part of “ERP” software.
Typical CAMM system provides:
• Decision support for equipment
• Reliability management
• Real time data capture for condition monitoring of equipment
• Work orders management
• Planning spares requirements
• Planning maintenance budgets
• Monitoring of labour productivity
• Comprehensive equipment databases
• Automatic sequencing of inspections
A typical planned maintenance package consists of three modules:
1. Maintenance administration and control
3. Maintenance operations
The Maintenance Administration and control records and maintains plant and policy related master information including information pertaining to basic organisational details. In addition the module facilitates housekeeping of data by allowing purging of excess maintenance related data.
The equipment module maintains master information and the maintenance history of equipment. Details of equipment hierarchies, dependencies, parameters and attached rotatables can be recorded. This module aids analysis and review of maintenance history by providing information from various perspectives.
The maintenance operations module deals with activities related to generation and creation of work requests and work orders and all planning activities. This module also maintains master information about the maintenance activities such as standard tasks, preventive maintenance and so on.
The basic hardware required is a server where all data are stored which is connected to different clients situated in different user sections.
I. CONTROL MODULE
Deals with recording essential information required for usage of CAMM system. The information specified here deals with basic organisational details like shift records, standard pay rates for labour, employee details, etc.
Control module involves the following functions:
i. Work groups – assigns the responsibility of carrying out work orders to work groups.
ii. Resources – has facility to define employee, contract and others (forklift, cranes). For employees carrying out maintenance tasks, employee’s personal details, shift details, employee cost, overtime costs and skill details are obtained. These details are used for planning and costing of maintenance jobs.
iii. Maintenance period and year – facility to define maintenance years to keep track of maintenance activities (this could differ from financial year).
iv. Location of equipment – Unlimited number of equipment locations for grouping equipment based on geographical, functional or planning attributes.
v. Authorisations – provision to define authorisation codes and associate employees with each code.
II. EQUIPMENT MODULE
Allows definition of equipment on which maintenance is to be carried out and also maintains an exhaustive maintenance history of the equipment. Documents, images, scanned drawings, drawing files, spreadsheets or almost anything that can be associated to equipment. At a later point of time, however, this can be retrieved and viewed for each equipment. Notes against each equipment can be maintained which can be retrieved and viewed for each equipment. Notes against each equipment can be maintained which can be referred to and updated frequently.
o Maintains complete history of all work performed on an equipment.
o Using this ,the complete maintenance history of an equipment can be reviewed, to plan it’s future maintenance activities.
o Facility to review the failure history of each equipment to determine various causes of breakdown.
o Facility to review the total maintenance expenses for each equipment.
o Maintains details of expenses on materials and resources separately.
CAMM system builds up maintenance history of equipment automatically when work orders are closed. The history details of equipment are displayed from different perspectives. Review options are available based on equipment, equipment location, work groups, and cost centers. The graphical trends of equipment history are based on cost resources and materials available. Apart from these data is available to analyse equipment failure, perform breakdowns and downtime analysis review maintenance cost, decision support for equipment, analyse material consumption and cost history.
III. MAINTENANCE OPERATIONS
o Allows building of a Trouble shooting guide.
o Maintains details of the equipment problems faced by maintenance personnel.
o Allows generation of emergency Work Orders.
o Allows corrective, preventive, predictive and breakdown work orders.
o Facilitates work order Planning and Scheduling.
o Enables work order reviews.
o Maintains details of contract jobs.
It is learnt that the following firms have implemented the CAMM System in their industries: Aaditya Cement, Bharat Earth Movers Ltd., Carborandum Universal, Indian Airlines, JK Industries, Maruthi Udyog Ltd., Parrys’ Confectionery Ltd., Hoosies Energy, USA, Trenergy, Malaysia.etc .The results are found to be excellent and the benefits are enormous. Let us hope that Computer adided Maintenance Management System will help Indian Industries to be cost effective and competitive in the global market by improving the capacity utilisation in the years to come.
CAMMS centralizes information
This article is based on material compiled for customers by University Computing Information Systems Manager Gary Miksik, Physical Plant Assistant Director Linda Michael and Physical Plant System Computer Coordinator Greg Baker.
Physical Plant has begun implementing a new software program called Maintenance Management Systems (MMS) that will allow their staff to better manage how they maintain IUB facilities. MMS will integrate a number of current data systems into one, so Physical Plant and other departments associated with facilities will have access to the same information. Rather than updating 10 different databases, we will only update one. The centralization of information will allow us to share data among all levels of Physical Plant. Full installation of the program is targeted for June 1999.
What does it mean to customers?
MMS will simplify how customers interact with Physical Plant by providing an easy-to-use way to request work. It will also keep our customers continually informed of the status and cost of the work Physical Plant is doing for them. Recording all maintenance activity in a single system will improve the quality of facilities information.
Why do we need MMS?
The current work-order system is almost 30 years old and is not flexible enough to meet the current needs of Physical Plant. The department currently communicates through many independent systems. Reporting on overall facilities operations is difficult because more than one person must maintain the same data on different systems.
What goals will MMS help Physical Plant meet?
MMS will have a significant impact on the maintenance, repair and construction of facilities by creating a standard system of work-order tracking, job-cost accounting, estimating, scheduling, project management, inventory control, preventive maintenance, property management and purchasing support for all types of work accomplished by IU facilities management departments. It will also:
• reduce the amount of unscheduled maintenance
• reduce paperwork associated with work management
• improve scheduling of work and timeliness of data for better customer feedback
• benchmark work performed by using a combination of government-published "engineering performance standards" and commercial cost data
• keep all facilities data on-line
• identify common work problems and trends
How does MMS tie into FIMS?
The Facilities Information Management System (FIMS) manages Indiana University's physical assets and operations, and is comprised of three major components:
2. CADD (Computer-Aided Design and Drafting), which creates electronic drawings of our facilities.
3. GIS (Geographic Information System), which captures, stores, updates, manipulates, displays and analyzes geographically-referenced information, such as a campus site plan, including utility lines, storm sewers, roads, sidewalks and trees.
What have we done with MMS so far?
Physical Plant purchased MMS from AEC (Architecture, Engineering and Construction) Data Systems in February, 1997. Miksik, Michael and Baker spent many months working with AEC to decide the best way to organize and meet work requirements. They have also taken steps to ensure that the new software gets properly configured to support Physical Plant's workflow and operating procedures.
In order to better understand the new system and test it "in the field," a pilot run on the system will be conducted in one of the maintenance zones for a three-month period. The pilot will process service requests, work orders, and preventive maintenance through the new software side by side with the current systems being used today. By running dual systems, Physical Plant can compare data to gauge effectiveness and identify problems.
When will Physical Plant start to use MMS?
Service requests, work-orders and preventive maintenance will become part of MMS as each becomes ready. The "readiness" of a unit will depend on the availability of computer equipment, networking connections and formal training on how to use the MMS software. Complete installation is expected for June 1999.
The AEC Data Systems' formal "train the trainer" program will develop "certified" trainers in-house, who will then be responsible for training all users of the new system. Physical Plant hired MMS Administrator Scott Knapp to ensure its success.
Maintenance operations module allows definition of master data required for tasks and procedures to be carried out on equipment to perform maintenance,. preventive maintenance and inspection schedules for each equipment part and resource requirement to perform the task can be specified alongwith the schedules. Schedules can be date based or usage based
Automatic generation of work orders based on schedules is a key feature of CAMM System. This happens when the automatic work order generation activity (also called period opening”) is carried out when period opening is attempted, the system identifies the tasks/procedures which are to be copied into work orders based on the schedules defined for each equipment.
1. The Marshal Book : RAMCO SYSTEMS
2. Operations, Planning and Control : IGNOU
3. Maximo Enterprise Features Guide.
• PRINCIPAL OBJECTIVES OF MAINTENANCE
• TYPES OF MAINTENANCE SYSTEM
• CONTROL MODULE
• EQUIPMENT MODULE
• MAINTENANCE OPERATIONS
• CASE STUDY