Asset Optimization Solutions

Asset Optimization Solutions

Will Help to identify and Improve the true Potential of existing Plant and Machinery

MES

Manufac turing Exec ution System

Business Concerns related to Production

• Not getting the desired output from every Production assets due to unplanned Downtime • Discrepancy in Design v/s Actual output from Production assets • Cannot realize full ROI on Investments made in Production assets • Data collected on the Shop floor not helping on proper Analysis to apply improvement measures • Unexplainable Delivery failures due to lack of authentic data • Availability, Rejection & Productivity not being appropriately measured so as to arrive at daily OEE across the plant • Figures such as OLE and OPE not available due to lack of correct data • Not able to apply TPM principles to help in CIP (Continuous Improvement Programs) to optimize on Asset Utilization for Production

The MES Overview

ERP

MES

Field Controls

System Architecture

MES System

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Production Data Options OR PLC in case of H/W Interfaces Machine Stoppage Data Options OR OR Data File Counter Data File HMI P.B. Panel

The MES Solution

• • • • A comprehensive Production MIS covering various reports required for standardization of information outputs An Integrated System to help in reducing Data Redundancy and provide Authentic data from the system on a regular basis Data can be captured either manually or through electronic interfaces with the Machines, if possible A Scalable application considering the future growth of the Organization making it compatible to TPM ideology

The MES Solution

• • • • • Will help to save on… - Time to analyze the daily production data.

- Time to analyze the daily Rejection data - Time to analyze the daily Production Lost time Data And will also provide OEE, OLE and OPE figures Will help to reduce the response time in analyzing the data and thus lead management in taking timely action wherever required Offers data Security at multiple levels of Management Standardize the reporting system for all the Sections and Machines throughout the organization

The MES Solution

• • • Store Production Data in a Database Server instead of discrete files to minimize the risk of Data loss Objective based Implementation will help to successfully deploy the system in your Organization Is closely integrated with our existing FTM System as part of your daily workflow

MES is fast to Deploy & Easy to use !!!

Asset Maintenanc e

Business Concerns related to Maintenance

• Productivity being directly hampered because of Breakdowns • Repetitive problems decreasing the overall efficiency of Machines • A lot of time being spent by Maintenance before Audits due to lack of proper records being maintained • Lack of proper Spares Management increasing cost of Maintenance • Non-compliance to Preventive Maintenance schedules • Not able to correctly quantify planned v/s unplanned maintenance jobs • Doubts in Reliability of all Corrective Maintenance jobs • Not realizing the full potential of TPM philosophy – Kaizens, Jishu Hozen, 5S, etc. not being implemented practically on a long term basis • Not able to set Performance Measurement Benchmarks and targets to improve upon Maintenance operations • Maintenance being demoralized due to criticism by everyone in spite of extra hours being spent in the plant

The Factory Factory Prodn. Divn. 1 Prodn. Divn. 2 Prodn. Divn. 3 Section 1 Section 2 & Machine 1 Machine 2 Attached Documents 4 Level Machine Breakup Specific Spares Instruments & Gauges Work Management B/D PRTL

Jobs Affecting Production

OPRT SERV PM / ABPM REPRS

Jobs Not Affecting Production

MISC (User Defined) CB

Work Management

The Fault Tree

Fault Nature

Fault Code

Cause Cause 1 Cause 2 B/D PRTL OPRT SERV PM / ABPM REPRS MISC (User Defined) CB & Resource Management

Man Power Spares

Internal External Consumable Recyclable Or Repairable

The FTM Solution focuses on …

• • • • • • Improving Production Uptime - By monitoring % Breakdown, MTBF & MTTR Plant Health & Operating Costs Machine-wise Maintenance Cost - By getting Spares and Manpower cost Effective Spares Management Effective Repairs Management – Track the Recycling of Spares Root Cause Failure Analysis by eliminating repetitive failures

The FTM Solution focuses on …

• • • • • • Developing a Centralized Knowledge Base Streamlining the Workflow & Quantifying your Work Improving PM, Proactive Jobs & Condition Monitoring Optimum Utilization of Resources Effective & Timely Documentation Realizing Total Plant Reliability

The FTM Helps to Achieve

     RCM - Reliability Centered Maintenance CBM - Condition Based Maintenance TBM - Time Based Maintenance RCFA - Root Cause Failure Analysis

CIP

- Continuous Improvement Processes

FTM is fast to Deploy & Easy to use !!!

Contact Information

Werardt Systemss Pvt Ltd

Pune, India Phone : 91-20-25285256, 25285257 Website : http://www.werardt.com

email: [email protected]