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FTM – Fault Tree Maintenance

An Online Maintenance Management System

Presents

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•Simplify your work flow for better management

•Get information on % Breakdown, MTBF and MTTR

•Increase all Opportunity maintenance jobs, be Proactive

•Enhance the power of PM

•Make TPM a part of your life

•Monitor machine wise consumption of Spares

•Strengthen Resource Management and Cost control

•Helps in monitoring your Utility Equipment

•Useful for ISO / QS / TS and reduces audit preparations

•System deployment is swift and smooth

FTM will help achieve your Primary Objective of Eliminating

Stoppages due to Maintenance using the Fault Tree Technique

System Overview

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• Productivity being directly hampered because of Breakdowns

• Repetitive problems decreasing the overall efficiency of Machines

• 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 correctly quantify planned v/s unplanned maintenance jobs

• Non-compliance to Preventive Maintenance schedules

• Doubts in Reliability of all Corrective Maintenance jobs

• Lack of proper Spares Management increasing cost of Maintenance

• Time being spent by Maintenance before Audits due to improper documentation

• Not able to set Performance Measurement Benchmarks and targets to improve

upon Maintenance operations

Business Concerns related to Maintenance

These could vary from Plant to Plant based on the Manufacturing setups

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The FTM Solution focuses on …

•Improving Production Uptime - By monitoring % Breakdown, MTBF & MTTR

•Root Cause Failure Analysis too help in eliminating repetitive failures

•Applying the basics of TPM philosophy pertaining to Maintenance

•Quantifying Maintenance work orders for resource planning

•Making PM simple and dynamic so as to comply to schedules

•Reliability of work to enhance Plant Health

•Operating Costs by providing Spares Consumption, Inventory Management

and Repairs Management

•Creating proper Performance Benchmarks to measure Maintenance

effectiveness

•Providing Analysis to assist in applying Continuous Improvement measures

•Maintaining Effective and Timely Documentation

Quantify your work to enhance Operations !

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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)

This Focus will help achieve

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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,

• Equipment or Machine or Tag No.

• Section or Workshop or Line or Channel or Cell

• Production Division or Building or Unit or Plant

• Job Request or Work Order or Work Request

• …

So on and so forth … and Multi-Lingual as well!!!

During Startup FTM can be configured to use your Terminologies!!!

User Defined Terminologies

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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.

Workflow Management in FTM

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•B/D Breakdown Jobs

•PRTL Partial Breakdowns

•OPRT Opportunity Maintenance Jobs

•SERV Service Jobs

•MISC Miscellaneous Jobs

•PM Preventive Maintenance Jobs

•ABPM Activity Based PM

•REPRS Repairs of Spares

•CB Instrument Calibration

•R/M Reconditioning & Modifications

•… and others

Jobs Affecting Production (Downtime Jobs)

Jobs Not Affecting Production (Zero Downtime Jobs)

Various types of Work Orders or Jobs in FTM

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Prodn. Divn. 3

Factory

Prodn. Divn. 1

Prodn. Divn. 2

Section 1 Section 2

Machine 1 Machine 2

Attached Documents

4 Level Machine Breakup

Specific Spares

Instruments & Gauges

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

Jobs Affecting

Production

Jobs Not Affecting

Production

Your Factory and Work Management

Your Setup Work Management

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B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

Man Power Spares

Internal External

ConsumableRecyclable

OrRepairable

The Fault Tree

Fault Nature

Fault Code

Cause

Cause 1

Cause 2

Work & Resource Management

Work Management Resource Management

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•Developing a Centralized Knowledge Base

•Streamlining the Workflow & Quantifying your Work

•Improving PM, Proactive Jobs & Condition Monitoring

•Utility Equipment Monitoring

•Optimum Utilization of Resources

•Effective & Timely Documentation

•Realizing Total Plant Reliability

In short the system focuses on …

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• This is mapping of your Department functioning on your Plant.

• Do you have a Centralized or Distributed Maintenance Setup,

i.e. Who is looking after which area of the plant?

• How your Trade departments or Disciplines (Mechanical,

Electrical, etc.) are handling their Jobs.

• How many Log Books do you maintain?

• This will help you in mapping your activities in the FTM Work

flow and thus help in streamlining your work

Maintenance Functionality

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•SKF Bearings Group

•Tetra Pak India

•Sandvik Asia

•Coca Cola India

•Bosch Group

•ThyssenKrupp Steels

•Alstom Power

•Asahi Float Glass

•Legrand Switchgear

•Seco Tools

•Elecon Engineering

•Cipla Pharmaceuticals Group

•And various others forming a base of over 40 Installations !

Some of our Clients in India

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•% Breakdown

•% Breakdown (With % of Money Lost)

•Machine History Summary with MTBF

•Breakdown Analysis & MTTR

•Pareto Analysis

•Fault Tree Analysis

•Breakdown Analysis Review

•Spares Consumption Analysis

•List of Pending Jobs

•Resource or Manpower Summary

•PM Schedule & Master Checklist

•PM Checklist (Pending)

Some of the Reports

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NOTE : There are overall 3 to 4 formats for the % Breakdown reports,

% Breakdown

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% Breakdown (With % of Money Lost)

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NOTE : This is available Section wise and Machine wise

Machine History Summary with MTBF & MTTR

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NOTE : This is available at Plant Level, Section Level & Machine Level

Breakdown Analysis & MTTR

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NOTE : This is available at plant Level, Section Level & Machine Level

Pareto Analysis

20NOTE : For All Sections, Particular Section, Particular Machine, Fault wise, etc.

Fault Tree Analysis

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Breakdown Analysis Review

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NOTE : This is available Spare Part wise, Section wise or Machine wise

Spares Consumption Analysis

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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 LtdPune, India

Phone : 91-20-25285256, 25285257

Website : http://www.werardt.com

email: business@werardt.com