Organizational for implementation of a computerized maintenance management program is one of the job of project team. Its implementation system and definition of the items would have to be stated as follows: The performance of the maintenance function planning and scheduling.
A. The performance of the front - end load semi permanent information such as cost centre, employed list ,parts list and equipment list, cause code ,action code, budget or other information that is not changed on a daily and weekly basis, The definition of sequence necessary for the loading of this data are also included.
B. The system of maintenance of the files on a daily and weekly basis involves several persons such as: i) A planner to load work orders. ii) A time clerk to load employees time sheets , iii). A store room clerk to load material requisition or any other appropriate combination. It is advisable to have individual information flowchart for streamlining of the system information ..
C, The performance of the security that is going to be part of the system, The definition and the procedure that should be established as to who could enter and or modify information in the system various segment and reports updates.
D. Th performance form of data entry should also be designed for data entry, they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
The orientation of the various people concerned with the new computerized maintenance management program is most important step after the organization. This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff. The detail of the maintenance appropriate for the various groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different. The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program. The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures for correct data inputs.
---Appropriate maintenance personnel planners and supervisors etc plans on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance management is a demanding task, the benefit are normally significant, but it will enhance the following :Better labor utilization., 5 to 23%
Equipment utilization 1 to 5%
Stores inventory reduction 10 to 20%, (Richard,2005).
Thursday, August 18, 2016
COMPUTERIzED MAINTENANCE MANAGEMENT
Organizational for implementation of a computerized maintenance management program is one of the job of project team. Its implementation system and definition of the items would have to be stated as follows:The performance of the maintenance function planning and scheduling.
A. The performance of the front - end load semi permanent information such as cost centre,employed list ,parts list and equipment list, cause code ,action code,budget or other information that is not changed on a daily and weekly basis,The definition of sequence necessary for the loading of this data are also included.
B.The system of maintenance of the files on a daily and weekly basis involves several persons such as: i) A planner to load work orders. ii) A time clerk to load employees time sheets,iii). A store room clerk to load material requisition or any other appropriate combination.It is advisable to have individual information flowchart for streamlining of the system information ..
C,The performance of the security that is going to be part of the system, The definition and the procedure that should be established as to who could enter and or modify information in the system various segment and reports updates.
D. Th performance form of data entry should also be designed for data entry,they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
The orientation of the various people concerned with the new computerized maintenance management program is most important step after the organization.This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff.The detail of the maintenance appropriate for the various groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different.The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program.The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures for correct data inputs.
---Appropriate maintenance personnel (planners,supervisors etc) on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance management is a demanding task,the benefit are normally significant,but it will enhance the following :Better labor utilization., 5 to 23%
Equipment utilization 1 to 5%
Stores inventory reduction 10 to 20%, (Richard,2005).
A. The performance of the front - end load semi permanent information such as cost centre,employed list ,parts list and equipment list, cause code ,action code,budget or other information that is not changed on a daily and weekly basis,The definition of sequence necessary for the loading of this data are also included.
B.The system of maintenance of the files on a daily and weekly basis involves several persons such as: i) A planner to load work orders. ii) A time clerk to load employees time sheets,iii). A store room clerk to load material requisition or any other appropriate combination.It is advisable to have individual information flowchart for streamlining of the system information ..
C,The performance of the security that is going to be part of the system, The definition and the procedure that should be established as to who could enter and or modify information in the system various segment and reports updates.
D. Th performance form of data entry should also be designed for data entry,they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
The orientation of the various people concerned with the new computerized maintenance management program is most important step after the organization.This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff.The detail of the maintenance appropriate for the various groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different.The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program.The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures for correct data inputs.
---Appropriate maintenance personnel (planners,supervisors etc) on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance management is a demanding task,the benefit are normally significant,but it will enhance the following :Better labor utilization., 5 to 23%
Equipment utilization 1 to 5%
Stores inventory reduction 10 to 20%, (Richard,2005).
Sunday, August 14, 2016
MAINTENANCE REPORTING SYSTEM , CONTINUE -1
The maintenance department will assigned the service number as it received the work order and will then multiply the two numbers to achieve a priority number in each work order.,The lowest priority is then the number 2 and the highest priority is 90, the work order with highest priority number should be schedule first. A portion of the maintenance hour available,starting from 10 to 30 percent should be assigned to priority work lower than 30. This priority considers potential failure costs and keeps low priority equipment and department operating. The control aspect of PS is two fold The average PS by craft, identifies how important the backlog is for each craft and for maintenance in total.The average PS number by production department and or in the case of multiple plants provides knowledge of the average level of maintenance.The PS number and man hour weighted average involved for each craft and each production involvement is calculated.The constrains of the activity can also be determined through the man hour of activity nodes and network evaluation data .Therefore the lower the man hour of any activity the easier to approach, but in most maintenance activity there is always a case sensitive and priority.,For instance, compare two jobs,one has a PS number of 90 and requires 3 man hours of work by an electrician or mechanic,Another has a PS number of 30. and requires 1 man hour of work by an electrician. The weighted average would be :
90 PS x 3 man hour = 270
30 PS x 1 man hour = 30
addition of the man hours is equal to 300 man hour divided by the total man hour,would results to ,75 average.The minimum use of a system will easily identify acceptable control limits for many things, for example:
1.Authorize overtime for a work order with a PS number of 42 and higher
2.Sub- contract or add man hour in a craft with an average number of PS number of 56 or higher for more than 4 weeks and a constant trend up.
3.Transfer assigned manpower from lower priority to higher priority departments until the average PS number in the department reaches 42 or lower. ---------
90 PS x 3 man hour = 270
30 PS x 1 man hour = 30
addition of the man hours is equal to 300 man hour divided by the total man hour,would results to ,75 average.The minimum use of a system will easily identify acceptable control limits for many things, for example:
1.Authorize overtime for a work order with a PS number of 42 and higher
2.Sub- contract or add man hour in a craft with an average number of PS number of 56 or higher for more than 4 weeks and a constant trend up.
3.Transfer assigned manpower from lower priority to higher priority departments until the average PS number in the department reaches 42 or lower. ---------
Thursday, August 11, 2016
MAINTENANCE REPORTING SYSTEM AND CONTROL
The most important aspect of any maintenance control system is priority systems that gives recognition to every piece of equipment in the plant .It must considers the plant utility and their transaction lines and various aspects of safety and environmental work.It must be simple enough for all to understand,rigid enough not to be abused, and flexible to covert the changing condition. The system below shows how to properly handle this basis Its most important is that, it is a priority system assigned by both production and maintenance .
Priority system for planning and scheduling of all maintenance work are as follows and are arranged in order of priority as shown below
Production Assisted work description Maintenance Assisted work description
8. Equipment that will shut down an entire department 7. Preventive maintenance production
if not operating.
ed during production.
department if not running. Equipment that will shutdown not running.Shut down of a department
an entire department if not running ,when installed spares or major system Normal are available for immediate operation. health and safety work.
ment that is important to the operation of a
3.Shop work or other routinework a department but will not shut down the department of
4.Auxiliary equip non repairs due to spare parts or units are
cause a major loss if not operating. available for immediate production runs
.
2.Convenient items,cost saving equipment ,
building roads 1.Painting for appearance or protection.
The use of skill crafts for cleanup . other than their work
.
To set up the PS system,identify every piece of equipment in the plant with production assigned even numbers published this list to all concerned and ascertain they thoroughly understand the concept.The production number should then be identified,on every work order in the case of dual purpose equipment or debatable number consider the productivity of the product and production schedules in assigning the production numbers. The production number can be change several times in a year to handle seasonal work and drastic changes in schedules.(Beachleg,1995.).
Priority system for planning and scheduling of all maintenance work are as follows and are arranged in order of priority as shown below
Production Assisted work description Maintenance Assisted work description
10. Equipment which will shut down the entire plant 9. Breakdown safety hazards where loss
if not operating .All safety work orders. of life or limb is probable. 8. Equipment that will shut down an entire department 7. Preventive maintenance production
if not operating.
- assistance.maintenance perform
ed during production.
- 6 Equipment that will reduce the output of the 5 Repair to major parts or units that are
department if not running. Equipment that will shutdown not running.Shut down of a department
an entire department if not running ,when installed spares or major system Normal are available for immediate operation. health and safety work.
ment that is important to the operation of a
3.Shop work or other routinework a department but will not shut down the department of
4.Auxiliary equip non repairs due to spare parts or units are
cause a major loss if not operating. available for immediate production runs
.
2.Convenient items,cost saving equipment ,
building roads 1.Painting for appearance or protection.
The use of skill crafts for cleanup . other than their work
.
To set up the PS system,identify every piece of equipment in the plant with production assigned even numbers published this list to all concerned and ascertain they thoroughly understand the concept.The production number should then be identified,on every work order in the case of dual purpose equipment or debatable number consider the productivity of the product and production schedules in assigning the production numbers. The production number can be change several times in a year to handle seasonal work and drastic changes in schedules.(Beachleg,1995.).
Thursday, August 4, 2016
THE MAINTENANCE REPORTING SYSTEM AND CONTROL
The maintenance steps being presented is a complete set of reports for control of a large and complex organisation, Those that involved in smaller and simpler operation may thus select the appropriate report that suits their organisation or specific situation.In most larger organisation which commonly used computer automation to record ,store ,calculate , and print reports.Smaller organisation generally must accomplished all these manually.The specific recommendation for smaller organisation are herein stated for their necessity, importance and values ,control reports must be sufficient ,correct information and decision must be made at the most appropriate period .The old methods of operating a maintenance department by recording only cost and evaluation is fast disappearing. Therefore the maintenance control should include the proper automation system, for correlation of the following:preventive ,corrective.predictive maintenance techniques,routine,spares,work on down time and failure mode.work during production,minor alteration and construction,,safety of the environment and others.
Maintenance must be control on short ranges and annual basis to balance a major project activity and provide for orderly vacation and long range basis (over 1 to 10 years or more) to assure proper skill, space and equipment as needed (Enest,1995). The maintenance function is not a separate entity, though not even pure overhead but it is just as important as any other function .Though the relationship to stores, accounting ,engineering and other functions will be properly identified by reports Below are summary of some of the reports that will be detailed as the discussion continues :- Average PS number_indicates how important is the known work,by technical and production department .
.Backlog of activity :Indicates how work would be required or could be stated as total work required.
-available to work.
-amount of work to be done or total work.
-labour sufficiency
-schedule compliance
-materials cost.
-present down time
-total department involved...
. .
Maintenance must be control on short ranges and annual basis to balance a major project activity and provide for orderly vacation and long range basis (over 1 to 10 years or more) to assure proper skill, space and equipment as needed (Enest,1995). The maintenance function is not a separate entity, though not even pure overhead but it is just as important as any other function .Though the relationship to stores, accounting ,engineering and other functions will be properly identified by reports Below are summary of some of the reports that will be detailed as the discussion continues :- Average PS number_indicates how important is the known work,by technical and production department .
.Backlog of activity :Indicates how work would be required or could be stated as total work required.
-available to work.
-amount of work to be done or total work.
-labour sufficiency
-schedule compliance
-materials cost.
-present down time
-total department involved...
. .
STRATEGY MANAGEMENT IMPLEMENTATION ,
For strategy implementation,manager begin by planning how they will put the strategy into action.They determined the resources and the activities necessary to implement the strategy, then they use the organization resources to carry out the plans.They manages who do not have much say in the organizations overall strategy and could apply thinking to the way their group helps implement that strategy.Given the key role that human resources play in sustaining a competitive advantage ,strategy implementation depends on the on effectively managing the human resources and applying the principle of organizational behavior which indicates that managers must lead their employees they must link individual skills,personalities and the like to work requirements..They must create a climate an organizational that foster motivation, communication and opportunities to contributes to group and individual goals.And manager must structure the organisation in such a way that it supports these activities.Today,s environment increasingly favors engineering organisation where a managers implement strategy by setting up an environment in which an employee could perform well,and getting out of professional orientation.In other words the manager gives the employee vision, the resources, the need to do their jobs and authority to make decisions.
STRATEGY CONTROL:Once the implementation of management of maintenance is under way managers would review the outcome of their efforts They need to see whether carrying out their plans might actually leads to implement its strategy. In addition,if the results are not actually what had been desired. They must considered whether organization needs to modify its strategy, in this way the organization performance influences future strategy formulation and planning.This feedback from control highlights an important aspect of strategy management of modern organization. It takes place in an environment of rapid and pervasive change. In such environment managers cannot afford to think of formulating a strategy as taking out of position.
This view result in a rapid strategy that slow down the organization when changes in the environment makes the strategy make absolute. Managers need to used feedback from strategy control along with information about the environment to device and revise strategies that encourage flexibility. The organization that are flexible in this sense will choose from among the tactics and control measures described herein .
.
STRATEGY CONTROL:Once the implementation of management of maintenance is under way managers would review the outcome of their efforts They need to see whether carrying out their plans might actually leads to implement its strategy. In addition,if the results are not actually what had been desired. They must considered whether organization needs to modify its strategy, in this way the organization performance influences future strategy formulation and planning.This feedback from control highlights an important aspect of strategy management of modern organization. It takes place in an environment of rapid and pervasive change. In such environment managers cannot afford to think of formulating a strategy as taking out of position.
This view result in a rapid strategy that slow down the organization when changes in the environment makes the strategy make absolute. Managers need to used feedback from strategy control along with information about the environment to device and revise strategies that encourage flexibility. The organization that are flexible in this sense will choose from among the tactics and control measures described herein .
.
Monday, August 1, 2016
THE FUTURE OF PROGRAMMABLE CONTROLLER.
The future of the programmable controllers relies not only on the continuation of the new product developments but also on the integration of the PLCs with other control and factory management equipment PLCs are incorporated through network into computer integration Manufacturing (CIM) system,Combining their power and resources with numerical controls, robots,CAD and CAM systems,personal computer based systems and hierarchical computer based system. There is no doubt that programmable controller will play a substantial role in the factory of the future.
Programmable controllers new advance technology includes features such as better operate interfaces,graphic user interface (GUIs) and more human oriented man and machine interfaces (such as voice modules) they also includes the development of interfaces that allow communication with the equipment, hardware, software that supports artificial intelligence,such as fuzzy logic i and o systems.
Software advances provide better connection between different equipment,using communication standards through widely used networks. New PLC instructions are developed out of the need to add intelligence to a controller, knowledge based on process learning type instruction may be introduced to enhance the capabilities of a system.The user;s concept of the Flexible Manufacturing System (FMS) would determine the control philosophy of the future.The future would almost certainly continue to cost programmable controllers as an important player in the oil industry and factory.
Control strategies will be distributed with intelligence instead of being centralized.Super PLC would be used in plant automation and other applications requiring complex,calculation, network communication,supervision of smaller PLCs and machines controllers..
Programmable controllers new advance technology includes features such as better operate interfaces,graphic user interface (GUIs) and more human oriented man and machine interfaces (such as voice modules) they also includes the development of interfaces that allow communication with the equipment, hardware, software that supports artificial intelligence,such as fuzzy logic i and o systems.
Software advances provide better connection between different equipment,using communication standards through widely used networks. New PLC instructions are developed out of the need to add intelligence to a controller, knowledge based on process learning type instruction may be introduced to enhance the capabilities of a system.The user;s concept of the Flexible Manufacturing System (FMS) would determine the control philosophy of the future.The future would almost certainly continue to cost programmable controllers as an important player in the oil industry and factory.
Control strategies will be distributed with intelligence instead of being centralized.Super PLC would be used in plant automation and other applications requiring complex,calculation, network communication,supervision of smaller PLCs and machines controllers..
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