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導入資訊管理系統對設備保養管理之影響
The Impact of Implementing MIS on
Maintenance Management
報告人﹕游禎平
2007/12/11
Management Information System
Efrain Turban, R. Kelly Rainer and Richard E. Potter,
2003
 Typically, a functional MIS provides periodic
reports about such topics
 operational efficiency(經營效率)
 effectiveness (效益)
 productivity (生產力)
 It prepares the reports by extracting
information from the corporate database and
processing it according to the needs of the
users (依據使用者需要從公司的資料庫萃取產生報表)
Table of Contents
1.Introduction: Maintenance Management
2. Development of Computerized maintenance
management system (CMMS): Procedure,
Structure,Tool
3. CMMS Application and Evaluation: Case study
4. Conclusions and Directions for Future Research
Table of Contents
1.Introduction: Maintenance Management
2. Development of Computerized maintenance
management system (CMMS): Procedure,
Structure,Tool
3. CMMS Application and Evaluation: Case study
4. Conclusions and Directions for Future Research
1. Maintenance Management
故障保養
預防保養
生產保養
全員生產保養
預知保養
全員生產管理
2.Maintenance/asset management strategy
Maintenance/Asset Strategy (保養策略)
Continuous
Improvement
(持續改善)
Total
Productive
Maintenance
Preventive
Maintenance
Stores and
Procurement
Financial
Optimization
Operations
Involvement
Work Flow
System
Reliability
Centered
Maintenance
CMMS/
Enterprise
Asset
Management
Productive Management(生產管理)
Technical and
Interpersonal
Training
Table of Contents
1.Introduction: Maintenance Management
2. Development of Computerized maintenance
management system (CMMS): Procedure,
Structure,Tool
3. CMMS Application and Evaluation: Case study
4. Conclusion and Directions for Future Researches
Computerized Maintenance Management System
稽核
訓練
組織
計畫
時程
診斷
標準
設備履歷
控制報表
Objectives
1. To reduce equipment breakdown. (降低設備故障)
2. To promote productive efficiency. (提升生產效率)
3. To reduce equipment maintenance cost. (降低維修成本)
4. To reduce inventory cost and achieve
reasonable inventory (service level). (降低備品庫存)
5. To build knowledge management,
troubleshooting technique and repair experience
can share. (建立故障檢修知識庫)
6.To develop human resource, promote(開發人力資源)
maintenance technical personnel efficiency.
1. Structure of Maintenance Management System
machine
PLC Control System
ActiveX Controls
e.g., RSView, VB
data collection
web-based
report
Link
(communication tool)
Reporting
data collection
Reporting
CMMS
Client
Production Server
Reporting
data collection
Reporting
Database
(SQL Server or Oracle)
2. Procedures of Maintenance Management System
(1). Definition HMI SCADA.(定義人機介面)
(2). Build equipment maintenance database. .
(建立設備保養資料庫)
(3). Computerized maintenance management system.
(設備保養管理電腦化)
Then, System evaluation and analysis.
(1) Definition HMI SCADA
 The software about HMI, it designed for
manufacturing efficiency, convenient operation
and production quality, etc.
 HMI is very useful, and we can define the HMI
for equipment maintenance by technician also.
 The HMI has many brands. There are many
software available. This research adopts RS-view
which is made by Rockwell Automation
Company.
(1) Definition HMI SCADA
(1) Definition HMI SCADA
Define Tag Number
( Mapping PLC address)
Build Graphics
Modify Graphics
(1) Definition HMI SCADA
(1) Definition HMI SCADA
(1) Definition HMI SCADA
(2) Build equipment maintenance database
(2) Build equipment maintenance database
(3) Computerized maintenance management system
DEMO
MMS in the past (1992~2002)
設備故障
When Equipment
breakdown
主管派工
Supervisor detach repair
worksheet (by manual)
Make decision for maintenance
period by supervisor
Preventive
maintenance
job
with
Look up for troubleshooting by technician
進行維修
Maintenance activity
填寫紀錄
Technicians make notes in worksheet
For instance: fault describe, labor and
materials
重點轉記
Supervisors write ponders able fault to
paper, collect to equipment’s curriculum
vitae document.
(can not analysis real-time)
文件歸檔
Store up maintenance document
reference, by future troubleshooting
for
保養履歷
Supervisors
refer
to
equipment’s
curriculum vitae document. Make decision
to maintenance policy. For instance:
decision period, replacement, training,
inventory, and efficiency.
Develop new CMMS (2004)
Analysis from DBMS
by computerized
建立資料庫 ,方便就源輸入!!
HMI definition
When Equipment
breakdown
Preventive
maintenance
Predicative
maintenance
Supervisor detach repair job from MIS print worksheet, technician
make equipment's rounds of inspection.
Reference from DBMS
Maintenance activity
Technicians make notes in worksheet
For instance: fault describe, labor and materials
Supervisor/ technician entry notes
maintenance management system database.
to
Automatic transfer to maintenance document in
database
for
reference,
by
future
troubleshooting
Supervisor refer and analysis from database. Make decision to
maintenance policy. For instance (decision period, replacement,
training, inventory, and efficiency)
機台自動
蒐集故障
訊息
E-R diagram for maintenance management
database
Maintenance Management Database
DEMO
Table of Contents
1.Introduction: Maintenance Management
2. Development of Computerized maintenance
management system (CMMS): Procedure,
Structure,Tool
3. CMMS Application and Evaluation: Case study
4. Conclusion and Directions for Future Researches
The background of case study
 This thesis collects seven months, November
2004 to May 2005, electrical equipment fault
event data from a chemical manufacturing
firm, about 3200 jobs being analyzed.

The case study company, an ISO9001 and
ISO14000 certificated company, produces
polyester fiber.

The company was established in October, 1967,
and is a full-processing manufacturer of
polyester filament and staple fiber.

In terms of capacity, the case study company is
the second largest polyester producer all over
the world, and is number one in Taiwan.
Access supports a variety of query types
(Access 支援各種查詢功能)
 These queries return data from one or more
tables and display the results in a result table.
 The table is updateable, which means that we
can change the data in the table and the
changes will be reflected in the underlying
tables.
 Selected queries can also be used to group rows
and calculate sums, counts, averages, and other
types of totals for these groups.
Search from maintenance management database
for estimating same equipment troubleshooting
times. (估計相同設備異常次數)
/*Access SQL language */
SELECT [Factory], [System], [Machine], [Date], [Fault describe]
FROM search MMS duplicate
WHERE [Factory] In (SELECT [Factory] FROM [search MMS
duplicate] As Tmp GROUP BY [Factory],[System],[Machine]
HAVING Count(*)>1 And [System] = [search MMS
duplicate].[System] And [Machine] = [search MMS
duplicate].[Machine])
ORDER BY [Factory], [System], [Machine];
/*END*/
Establish maintenance cycle
Search database forecasting equipments fault from MMS
(預測設備相同異常次數)
/*Access SQL language*/
The SQL
SELECT MMS.Date, MMS.[Fault describe], MMS.Factory,
MMS.System, MMS.Machine
FROM MMS
WHERE (((MMS.Date) In (SELECT [Date] FROM [MMS] As Tmp
GROUP BY [Date],[Fault descript] HAVING Count(*)>1 And [Fault
descript] = [MMS].[Fault descript])))
ORDER BY MMS.Date, MMS. [Fault descript];
/*END*/
Fault analyses for maintenance strategy
FAULT FREQUENCY ANALYSIS
30
25
COUNT
20
15
10
5
:9
84
交
訊
異
走 常
走
停
消
停
防
誤
動
無 作
法
加
無 熱
法
列
無 印
法
啟
無 動
法
顯
示
無
畫
面
源
代
異
脫
電
無
跳
開
啟
異
法
無
常
異
度
溫
常
異
位
定
行
走
常
0
CAUSE
Search from MMS database for estimating equipment
troubleshooting job that needs unspecified inventory
(預測設備相同元件損壞頻率)
/*Access SQL language*/
SELECT [MMS SEARCH COMPOENT]. Component, [MMS
SEARCH COMPOENT].[Job No], [MMS SEARCH
COMPOENT].Date, [MMS SEARCH COMPOENT].Factory, [MMS
SEARCH COMPOENT].System, [MMS SEARCH
COMPOENT].Machine, [MMS SEARCH
COMPOENT].[Maintenance Note], [MMS SEARCH
COMPOENT].Analysis, [MMS SEARCH COMPOENT].Strategy,
[MMS SEARCH COMPOENT].Classifies
FROM [MMS SEARCH COMPOENT]
WHERE ((([MMS SEARCH COMPOENT].Component) In
(SELECT [Component] FROM [MMS SEARCH COMPOENT] As
Tmp GROUP BY [Component] HAVING Count(*)>1 )))
ORDER BY [MMS SEARCH COMPOENT].Component;
/*END*/
0
BREAK
LINITE
TERMINAL
CYCLINDER
COM PRES SER
S ERVER
Y/F
TH
M OTOR
IOU
CABLE
S ENS OR
COPLING
FLOWER
YARN
BH
HEATER
PRESS URE
HEATER
S HUTTL
LIMIT
PCB
M OTOR
S OL
S ENS OR
QUALITY
Analysis of maintenance material requirement
INVENTORY ANALYSIS
30
25
20
15
10
5
COMPONENT
DEMO
Inventory Management Database
DEMO
Factory equipment breakdown ratio
A
factory
breakdown
analysis
0.60
Breakdown Ratio
0.50
0.40
0.30
0.20
0.10
0.00
2004/Jan
2004/Feb
2004/Mar
2004/Apr
2004/May
2004/Jun
2004/Jul
2004/Aug
2004/Sep
2004/Oct
2004/Nov
2004/Dec
2005/Jan
2005/Feb
2005/Mar
2005/Apr
2005/May
2004/Dec
2005/Jan
2005/Feb
2005/Mar
2005/Apr
2005/May
2004/Dec
2005/Jan
2005/Feb
2005/Mar
2005/Apr
2005/May
2005/Feb
2005/Mar
2005/Apr
2005/May
Month
9ABC SPINNING
9FG SPINNING
9ABC FIBER
9FG FIBER
B factory breakdown analysis
0.60
Breakdown Ratio
0.50
0.40
0.30
0.20
0.10
0.00
2004/Jan
2004/Feb
2004/Mar
2004/Apr
2004/May
2004/Jun
2004/Jul
2004/Aug
2004/Sep
2004/Oct
2004/Nov
Month
C factory
breakdown
analysis
PBF1
PBF2
PBF3
0.07
Breakdown Ratio
0.06
0.05
0.04
0.03
0.02
0.01
0.00
2004/Jan
2004/Feb
2004/Mar
2004/Apr
2004/May
2004/Jun
2004/Jul
2004/Aug
2004/Sep
2004/Oct
2004/Nov
Month
D factory breakdown analysis
spin
crimper
0.05
Breakdown Ratio
0.04
0.03
0.02
0.01
0.00
2004/Jan
2004/Feb
2004/Mar
2004/Apr
2004/May
2004/Jun
2004/Jul
2004/Aug
2004/Sep
Month
spin
crimper
2004/Oct
2004/Nov
2004/Dec
2005/Jan
Comparisons of breakdown ratio, with/without CMMS
Comparisons of factory maintenance
fees, with/without CMMS
All factory maintenance fee analysis
2000.00
1800.00
1600.00
Breakdown Ratio
1400.00
1200.00
1000.00
800.00
600.00
400.00
200.00
0.00
2004/Jan
2004/Feb
2004/Mar
2004/Apr
2004/May
2004/Jun
2004/Jul
2004/Aug
2004/Sep
2004/Oct
Month
A
B
C
D
2004/Nov
2004/Dec
2005/Jan
2005/Feb
2005/Mar
2005/Apr
2005/May
Comparisons of all factories
maintenance fee with/without CMMS
3. Knowledge Management
Knowledge Management Database
Evaluate CMMS for Knowledge Management
DEMO
Evaluate CMMS for Knowledge Management

CMMS can also function on sharing KM
maintenance knowledge, which has never
been measured by computer before.

The hands-on experience sharing has rapidly
enhanced the technician’s ability, resulting in
4 out of 72 workforce being saved.

The cost for cultivating a technician is about
NT$68,000/per month; the adoption of
CMMS system has saved NT$ 272,000/per
month for the case study company.
Apply this CMMS to link MIS of enterprise. We
perform maintenance management well. Refer to
the following description:
1. Define Maintenance Tasks (定義保養工作)
2. Plan Maintenance Work (計畫保養工作)
3. Update Work Order (更新派工)
4. Get Work Done in a Certain Period(限定完工期限)
5. List of Parts Re-Ordered (庫存備品採購)
6. For Conducting Training (員工訓練)
Table of Contents
1.Introduction: Maintenance Management
2. Development of Computerized maintenance
management system (CMMS): Procedure,
Structure,Tool
3. CMMS Application and Evaluation: Case study
4. Conclusions and Directions for Future Research
4.1 Conclusion





The goal of maintenance activity is to provide high
quality, low cost maintenance. (達成高品質低成本的目標)
A good maintenance management will definitely
reduce productive loss. (可減少生產損失)
Adoption of CMMS enhances the performance of
maintenance, inspection, monitoring, inventory, and
training, etc. (採用電腦化維修管理可以增強保養執行)
By integrating with Enterprise Resources Planning
(ERP) or MIS, we can perform better to maintenance
management. (採用電腦化維修管理方便與MIS整合)
CMMS, predictive and maintenance tracking systems
are now a necessary in managing and controlling
assets, plant and equipment maintenance in modern
manufacturing. (採用電腦化維修管理對現代製造業是必須的)
4.2 Directions for Future Researches
1. Re-manufacture, repair, and exchange services for
equipments and reliable parts; repair the third party’s
parts (low cost) and evaluate the using validity. (開發對抗
品,低價位可靠的備品)
2. Reduce the associated costs on site management of parts
inventories, and increase working time to ensure that
users have the right replacement parts.
(降低維修備品成本)
3. Combine CMMS systems with the existing or planning
control systems to increase real-time monitoring
capabilities. (結合CMMS增強即時監視能力)
4. Remote diagnostic services to increase facility uptime
and reduce overall labor expenses. (遠端維修減少人力浪費)
4.2 Directions for Future Research
5. Consult professionals and expertise to implement EAM
solutions without developing additional in-house expertise.
(委外顧問及專家)
6. Establish the predictive maintenance practices, which
display more effective than that of breakdown maintenance
techniques. (建立預知保養執行)
7. Ensure all HMI will automatically transform
to maintenance management database, in order to achieve
real-time trusty. (HMI自動轉換到維修管理系統)
8. Maintain Database for data security. (database維護及安全)
Thanks and giving suggestions