Siberian Chemical Plant implements the system of an avtomtization of management of repairs and maintenance

Siberian Chemical Plant implements the automation system of management of maintenance and repairs.

Task

At plant the corporate system of resource management of Alfa ERP is operated for a number of years. It covers management of finance, calculations and costs, contract activities, supply and warehouse logistics, fixed assets, accounting and tax accounting. Control automation of a MRO became the next logical step to creation of a single system of enterprise management.

Solution

By the beginning of the project several centralized systems on automation of a MRO (separately on the mechanical, utilities and instrument equipment) and also a number of separate tasks in divisions of plant worked at plant. Use of these systems was limited, generally to preparation and printout of diagrams of scheduled preventive maintenance.

Process of preparation of plans, taking into account the large volume of the serviced equipment, took long time, many transactions were executed manually or duplicated, in the course of formation of diagrams of repairs interaction between services of mechanics, power engineering specialists and instrument operators at accomplishment of repairs on the same equipment was not considered.

The specified problems also resulted in need of creation of the TOIR complete automated control system.

Implementation

More than 50 services were involved in the system of maintenance and repairs at plant, the expected amount of the register exceeded 140,000 thousand items of equipment therefore the decision was made that it is the most rational to begin with a pilot project. Services of chief specialists (departments of the chief mechanical engineer, power engineering specialist, instrument operator) and one of the main productions — the Plant of separation of isotopes were included in the list of "pilot" divisions. Such approach gave the chance within a pilot project to approve the solution of a number of the existing problems and to develop methodical recommendations for further replication.

In the course of replication data from 25 raznoformatny local systems of accounting of the equipment were processed, scanned, transferred to an electronic format and more than 7000 names from reference books on the common industrial equipment and the MRO systems are entered to the qualifier.

The solution of a problem of classification of the used equipment became one of important success factors of the project. Now for uniquely identifying of the name of the equipment, the information about its structure and data on standard repair work, it is rather correct to user to select value of the qualifier when entering the equipment in operation. It considerably simplifies the procedure of planning of repairs, excludes discrepancies in labor input assessment, allows to control repair costs by groups of classification of the equipment.

Automatic synchronization of terms of accomplishment of repairs for the "dependent" equipment allows to optimize quantity of outputs in repair, to reduce a downtime of the equipment and to reduce costs for accomplishment of scheduled works.

Results

As a result of project implementation at plant the single system of management of maintenance and repairs of the equipment allowing to control fully all process of hardware maintenance from the moment of its acquisition before the termination of life was created.

A system covered the divisions operating the equipment, controlling services of plant and division contractors of repairs.

Within the project audit of objects of the equipment was executed, positions of the equipment which is written off or being in preservation which were present at diagrams of repairs with the corresponding planned costs for accomplishment of these works earlier were excluded.

The created system gave the chance to coordinate in the automated mode of action for planning of scheduled works on the equipment for repair services of plant that allowed to optimize their work and as result, to reduce the general downtime of the equipment.

Integration with control block supply of the Alfa System allows to create the reasonable need for spare parts and materials, to control execution of requests and the actual availability of the materials necessary for accomplishment of repairs, and communication with an accounting subsystem — to keep account of actual costs in necessary analytical cuts and quantitative accounting of the material consumption on repairs.

Today in the created system about 140,000 items of equipment are serviced, more than 100 users from 23 divisions of plant work.