Transcript PowerPoint Presentation - Projects Data Management System

Presents
FTM – Fault Tree Maintenance
An Online Maintenance Management System
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System Overview
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Simplify your work flow for better management
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Get information on % Breakdown, MTBF and MTTR
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Increase all Opportunity maintenance jobs, be Proactive
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Enhance the power of PM
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Make TPM a part of your life
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Monitor machine wise consumption of Spares
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Strengthen Resource Management and Cost control
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Helps in monitoring your Utility Equipment
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Useful for ISO / QS / TS and reduces audit preparations
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System deployment is swift and smooth
FTM will help achieve your Primary Objective of Eliminating
Stoppages due to Maintenance using the Fault Tree Technique
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Business Concerns related to Maintenance
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Productivity being directly hampered because of Breakdowns
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Repetitive problems decreasing the overall efficiency of Machines
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Not realizing the full potential of TPM philosophy – Kaizens, Jishu Hozen, 5S, etc.
not being implemented practically on a long term basis
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Not able to correctly quantify planned v/s unplanned maintenance jobs
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Non-compliance to Preventive Maintenance schedules
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Doubts in Reliability of all Corrective Maintenance jobs
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Lack of proper Spares Management increasing cost of Maintenance
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Time being spent by Maintenance before Audits due to improper documentation
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Not able to set Performance Measurement Benchmarks and targets to improve
upon Maintenance operations
These could vary from Plant to Plant based on the Manufacturing setups
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The FTM Solution focuses on …
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Improving Production Uptime - By monitoring % Breakdown, MTBF & MTTR
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Root Cause Failure Analysis too help in eliminating repetitive failures
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Applying the basics of TPM philosophy pertaining to Maintenance
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Quantifying Maintenance work orders for resource planning
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Making PM simple and dynamic so as to comply to schedules
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Reliability of work to enhance Plant Health
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Operating Costs by providing Spares Consumption, Inventory Management
and Repairs Management
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Creating proper Performance Benchmarks to measure Maintenance
effectiveness
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Providing Analysis to assist in applying Continuous Improvement measures
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Maintaining Effective and Timely Documentation
Quantify your work to enhance Operations !
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This Focus will help achieve
RCM
- Reliability Centered Maintenance
CBM
- Condition Based Maintenance
TBM
- Time Based Maintenance
RCFA - Root Cause Failure Analysis
CIP
- Continuous Improvement Processes
This will help in realizing Total Plant Reliability (TPR)
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User Defined Terminologies
One excellent feature of the system is to adapt to the needs of the
culture of the organization. This starts with using the same
terminologies being used in the plant such as,
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Equipment or Machine or Tag No.
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Section or Workshop or Line or Channel or Cell
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Production Division or Building or Unit or Plant
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Job Request or Work Order or Work Request
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…
So on and so forth … and Multi-Lingual as well!!!
During Startup FTM can be configured to use your Terminologies!!!
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Workflow Management in FTM
The Offline Mode of Entry
In an Offline mode of data entry, the maintenance users do the Job
entries on their own. Then, based on the availability of time, these
Jobs will be entered in FTM say, at the end of the Shift or Day or
Week or even at the end of the Month.
The Online Mode of Entry
In an Online mode of data entry, the Production users will Log onto
FTM through the “Ftmweb” module and send a request to
Maintenance for attending a Job.
On the Maintenance users Pending Jobs screen a small screen will be
popped up to tell him that a new job has arrived which he then can
see in his Pending jobs list.
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Various types of Work Orders or Jobs in FTM
Jobs Affecting Production (Downtime Jobs)
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B/D
Breakdown Jobs
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PRTL
Partial Breakdowns
Jobs Not Affecting Production (Zero Downtime Jobs)
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OPRT
Opportunity Maintenance Jobs
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SERV
Service Jobs
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MISC
Miscellaneous Jobs
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PM
Preventive Maintenance Jobs
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ABPM
Activity Based PM
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REPRS
Repairs of Spares
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CB
Instrument Calibration
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R/M
Reconditioning & Modifications
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…
and others
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Your Factory and Work Management
Your Setup
Work Management
Factory
B/D
PRTL
Prodn.
Divn. 1
Prodn.
Divn. 2
Prodn.
Divn. 3
Jobs
Affecting
Production
OPRT
SERV
Section 1
PM / ABPM
Section 2
REPRS
Jobs Not
Affecting
Production
MISC (User Defined)
Machine 1
Attached
Documents
Machine 2
4 Level
Machine
Breakup
CB
Specific
Spares
Instruments
& Gauges
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Work & Resource Management
Work Management
The Fault Tree
Resource Management
B/D
Fault Nature
PRTL
Fault Code
OPRT
Cause
Man Power
Spares
SERV
Cause 1
Cause 2
PM / ABPM
Internal
External
REPRS
MISC (User Defined)
CB
Consumable
Recyclable
Or
Repairable
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In short the system focuses on …
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Developing a Centralized Knowledge Base
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Streamlining the Workflow & Quantifying your Work
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Improving PM, Proactive Jobs & Condition Monitoring
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Utility Equipment Monitoring
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Optimum Utilization of Resources
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Effective & Timely Documentation
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Realizing Total Plant Reliability
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Maintenance Functionality
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This is mapping of your Department functioning on your Plant.
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Do you have a Centralized or Distributed Maintenance Setup,
i.e. Who is looking after which area of the plant?
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How your Trade departments or Disciplines (Mechanical,
Electrical, etc.) are handling their Jobs.
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How many Log Books do you maintain?
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This will help you in mapping your activities in the FTM Work
flow and thus help in streamlining your work
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Some of our Clients in India
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SKF Bearings Group
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Tetra Pak India
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Sandvik Asia
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Coca Cola India
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Bosch Group
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ThyssenKrupp Steels
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Alstom Power
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Asahi Float Glass
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Legrand Switchgear
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Seco Tools
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Elecon Engineering
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Cipla Pharmaceuticals Group
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And various others forming
a base of over 40 Installations !
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Some of the Reports
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% Breakdown
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% Breakdown (With % of Money Lost)
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Machine History Summary with MTBF
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Breakdown Analysis & MTTR
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Pareto Analysis
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Fault Tree Analysis
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Breakdown Analysis Review
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Spares Consumption Analysis
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List of Pending Jobs
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Resource or Manpower Summary
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PM Schedule & Master Checklist
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PM Checklist (Pending)
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% Breakdown
NOTE : There are overall 3 to 4 formats for the % Breakdown reports,
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% Breakdown (With % of Money Lost)
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Machine History Summary with MTBF & MTTR
NOTE : This is available Section wise and Machine wise
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Breakdown Analysis & MTTR
NOTE : This is available at Plant Level, Section Level & Machine Level
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Pareto Analysis
NOTE : This is available at plant Level, Section Level & Machine Level
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Fault Tree Analysis
NOTE : For All Sections, Particular Section, Particular Machine, Fault wise, etc.
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Breakdown Analysis Review
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Spares Consumption Analysis
NOTE : This is available Spare Part wise, Section wise or Machine wise
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List of Pending Jobs
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Resource / Manpower Summary
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PM Schedule & Master Checklist
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PM Checklist Pending
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Contact Information
Werardt Systemss Pvt Ltd
Pune, India
Phone : 91-20-25285256, 25285257
Website : http://www.werardt.com
email: [email protected]
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