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...

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

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 )

Management Information System

Efrain Turban, R. Kelly Rainer and Richard E. Potter, 2003

Table of Contents1.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

Maintenance/Asset Strategy ( 保養策略 )

Continuous Improvement ( 持續改善 )

FinancialOptimization

Total Productive

Maintenance

Preventive Maintenance

OperationsInvolvement

Reliability Centered

Maintenance

Stores and Procurement

Work Flow System

CMMS/Enterprise

Asset Management

Technical and Interpersonal Training

Productive Management( 生產管理 )

2.Maintenance/asset management strategy

Table of Contents

1.Introduction: Maintenance Management

2. Development of Computerized maintenance

management system (CMMS): Procedure,

Structure,Tool


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

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.

Objectives

PLC Control System

Link (communication tool)

Database

(SQL Server or Oracle)

ActiveX Controls

e.g., RSView, VB

Production Server

web-based report

data collection

data collection

data collection Reporting

Reporting

Reporting

Reporting

1. Structure of Maintenance Management System

CMMSClient

machine

(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.

2. Procedures of Maintenance Management System

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

Define Tag Number( Mapping PLC address)

Build GraphicsModify Graphics


(2) Build equipment maintenance database

(3) Computerized maintenance management system

DEMO

Supervisor detach repair job with worksheet (by manual)

Maintenance activity

Technicians make notes in worksheetFor instance: fault describe, labor and materials

Supervisors write ponders able fault to paper, collect to equipment’s curriculum vitae document.(can not analysis real-time)

Store up maintenance document for reference, by future troubleshooting

When Equipment breakdown

Preventive maintenance

Supervisors refer to equipment’s curriculum vitae document. Make decision to maintenance policy. For instance: decision period, replacement, training, inventory, and efficiency.

Look up for troubleshooting by technician

Make decision for maintenance period by supervisor

MMS in the past (1992~2002)

設備故障

主管派工

進行維修

填寫紀錄

重點轉記

文件歸檔

保養履歷

Develop new CMMS (2004)

Supervisor detach repair job from MIS print worksheet, technician make equipment's rounds of inspection.

Maintenance activity

Technicians make notes in worksheetFor instance: fault describe, labor and materials

Supervisor/ technician entry notes to maintenance management system database.

Automatic transfer to maintenance document in database for reference, by future troubleshooting

When Equipment breakdown

Preventive maintenance

Supervisor refer and analysis from database. Make decision to maintenance policy. For instance (decision period, replacement, training, inventory, and efficiency)

Predicative maintenance

HMI definition

Analysis from DBMS

Reference from DBMS

by computerized建立資料庫 ,方便就源輸入 !! 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 man

agement system (CMMS): Procedure, Structure,

Tool


4. Conclusion and Directions for Future Researches

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.

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 background of case study

Access supports a variety of query types

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.

(Access 支援各種查詢功能 )

/*Access SQL language */SELECT [Factory], [System], [Machine], [Date], [Fault describe]FROM search MMS duplicateWHERE [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*/

Search from maintenance management database for estimating same equipment troubleshooting times. ( 估計相同設備異常次數 )

Establish maintenance cycle

/*Access SQL language*/The SQLSELECT MMS.Date, MMS.[Fault describe], MMS.Factory, MMS.System, MMS.MachineFROM MMSWHERE (((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*/

Search database forecasting equipments fault from MMS( 預測設備相同異常次數 )

FAULT FREQUENCY ANALYSIS

0

5

10

15

20

25

30

走行異常

定位異常

溫度異常

無法開啟跳脫無電源 :9

84

異代交訊異常

走走停停

消防誤動作

無法加熱

無法列印

無法啟動

無法顯示無畫面

CAUSE

CO

UN

T

Fault analyses for maintenance strategy

/*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].ClassifiesFROM [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*/

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 )

INVENTORY ANALYSIS

0

5

10

15

20

25

30

SEN

SO

R

SO

L

MO

TO

R

PC

B

LIM

IT

SH

UTTL

HEA

TE

R

PR

ESS

UR

E

HEA

TE

R

BH

YAR

N

FLO

WER

CO

PLI

NG

SEN

SO

R

CA

BLE IOU

MO

TO

R

TH

Y/F

SER

VE

R

CO

MPR

ESSE

R

CYC

LIN

DE

R

TER

MIN

AL

LIN

ITE

BR

EA

K

COMPONENT

QU

ALI

TY

Analysis of maintenance material requirement

DEMO

Inventory Management Database

DEMO

A f actory breakdown anal ysi s

0. 00

0. 10

0. 20

0. 30

0. 40

0. 50

0. 60

2004/ J an 2004/ Feb 2004/ Mar 2004/ Apr 2004/ May 2004/ J un 2004/ J ul 2004/ Aug 2004/ Sep 2004/ Oct 2004/ Nov 2004/ Dec 2005/ J an 2005/ Feb 2005/ Mar 2005/ Apr 2005/ May

Mont hBreakdow

n Ratio

9ABC SPI NNI NG 9FG SPI NNI NG 9ABC FI BER 9FG FI BER

B f actory breakdown anal ysi s

0. 00

0. 10

0. 20

0. 30

0. 40

0. 50

0. 60


Mont h

Bre

akdow

n R

atio

PBF1 PBF2 PBF3 C f actory breakdown anal ysi s

0. 00

0. 01

0. 02

0. 03

0. 04

0. 05

0. 06

0. 07


Mont h

Breakdow

n Ratio

spi n cr i mperD f actory breakdown anal ysi s

0. 00

0. 01

0. 02

0. 03

0. 04

0. 05


Month

Breakd

ow

n R

atio

spi n cri mper

Factory equipment breakdown ratio

Comparisons of breakdown ratio, with/without CMMS

All f actory mai ntenance f ee anal ysi s

0. 00

200. 00

400. 00

600. 00

800. 00

1000. 00

1200. 00

1400. 00

1600. 00

1800. 00

2000. 00


Mont h

Brea

kdow

n Ra

tio

A B C D

Comparisons of factory maintenance fees, with/without CMMS

Comparisons of all factories maintenance fee with/without CMMS

3. Knowledge Management

Knowledge Management Database

Evaluate CMMS for Knowledge Management

DEMO

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.

Evaluate CMMS for Knowledge Management

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 Management2. Development of Computerized maintenance man

agement system (CMMS): Procedure, Structure,Tool


4. Conclusions and Directions for Future Research

4.1 Conclusion

The goal of maintenance activity is to provide high q

uality, 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 )

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 )

4.2 Directions for Future Research

Thanks and giving suggestions

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...

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