IBM Maximo generation company

"IBM Maximo Asset Management" in JSC Generation Company holding.

The fifth stage of the project on implementation of ISU "TOIR" based on "IBM Maximo Asset Management" is completed. At present implementation of works on the sixth stage is begun.

The first stage of the project lasted from June to December, 2008 and was devoted to organizational solutions:

•   The project charter is approved, procedures of project management, etc. are approved;
•   Implementation strategies are developed;
•   The technique of formation of a system of qualifiers and NSI is developed;
•   Examinations of the enterprises of the Customer were conducted and following the results business processes on a MRO are simulated and described;
•   Technical specifications on implementation on three projects were developed and approved.

After the approval of terms of reference on implementation, it was necessary to pass directly to works on implementation of ISU "TOIR". Implementation was separated into two stages (2 and 3) which are conditionally called "Implementation of basic functionality" and "Implementation of complete functionality".

During the Second a project stage (2009) the basis for implementation and functioning of all system was created:

•   Competence Centers on the information system "IBM Maximo Asset Management" and on MRO methodology based on Tataisenergo LLC and in managements of the Customer are created;
•   The qualifier of assets containing more than 2000 positions and more than 2000 unique characteristics is created;
•   The qualifier of defects consisting of more than 180 classes of failure is created;
•   The qualifier of professions and positions of employees on the basis of OKPDTR is created;
•   The reference book of units of measure made according to OKEI (more than 1000 units) is created;
•   Reference books of locations (about 2000 on branch \the operational area) and assets are created (about 70,000 on branch or 40,000 on the operational area);
•   Auxiliary reference books (about 30) are created;
•   Integration from ISU "Parus" in reference books by employees, warehouses and a remaining balance of Inventories is performed;
•   Are implemented "The electronic journal of defects" and Certification started;
•   Primary customization of ISU "TOIR" - setup of access rights and homepages of users is performed;
•   Report settings and control performance indicators are carried out.

As a result execution of works in JSC Tatenergo holding the general normative and help base which allows to structure data on a MRO is entered and to obtain necessary information at any moment on any branch (JSC Group) \to the operational area (JSC KTK, JSC NChTK), using the configured control performance indicators and reports. For commissioning more than 700 users were trained in 5 different rates, User guides and presentation materials for training are created. With completion of these works input of ISU "TOIR" in operation on functional units "The electronic journal of defects" and Certification is announced.

The third stage of the project (2010) was generally devoted to implementation of methodology of planning and tracking of repairs.

The task was complicated by the considerable volume of work on integration of the IBM Maximo Asset Management system (ISU "TOIR") with ISU "Parus", the Grand estimate PC, the GIS "Zulu" and the Requests PC:

1.   an Elegant and qualification system – implementation of this completion (expansion of a system) required as works of programmers on completion of standard functionality of applications, and laborious work of the consultant-methodologist as it was necessary to consider all restrictions imposed by Safety regulations and strict business processes of issue and accounting of dresses.
2.   the Magazine of requests for output \input of the equipment – this task required the solution not only on setup of the new application, but also system integration with the Requests PC as the data transferred from ISU "TOIR" were necessary for a task of an operation mode of the equipment and approval of the third party – the System Operator of Tatarstan. This business process is not only directly business process of a MRO, but also one of the most important processes for business of the Customer and energy security of all region.
3.   Development of methodology of planning of influences and methodology of tracking of influences (planning, implementation and tracking of planned repair influences). Two these documents are in essence a cornerstone of all project – without development and deployment of the principles of planning of repairs the system of ISU "TOIR" loses the appointment. A guarantee of reliable operation of the equipment is carried out technical service and repair in time. Annually the Customer according to technical policy creates the "annual program of repairs" containing a list of repair work, their volume, carrying out terms, the list of necessary material resources, and estimated cost. According to the results of execution of the annual program adjustment of the perspective program is performed (for 3 years). At the moment works on formation of the perspective and annual plan in ISU "TOIR" come to an end.
4. Интеграция with ISU "Parus" - integration with ERP systems is one of the most important directions of any project on class EAM system implementation. During the second stage integration was caused by creation of the general normative and help base (the reference book by workers, the reference book of warehouses and remaining balance in warehouses). At the third stage the new tasks are set: transfer of reference books of partners and information on the cost of the works which are carried out on assets. This integration allows to consider more precisely the actual cost of the performed repair work, increasing detailing of distribution of cost of repair influences to nodes (parts) of process systems (units).
5.   Integration into the Grand-Smeta PC for information transfer at estimate costs of planned activities. The Grand-Smeta PC is one of leaders in the market of programs for estimating therefore the given solution on integration of Maximo Asset Management (the leader among EAM-systems) and the Grand-Smeta PC is valuable development of the company of Ltd company "OTR-2000.
6.   Integration with MS Project for planning of terms of repair work allows to submit graphically the schedule of works of the enterprises of the Customer, to create dependences between works and also to align terms of repairs and to monitor loading of personnel. This integration is intended to facilitate work to the services of the Customer responsible for work planning and also for approval of terms of repairs of external services (committee on rates, the system operator, etc.).
7. Интеграция with the module " The TEHNO software electronic archive allows to get access to already ready library of the electronic and scanned documents, namely – drawings, project and design documentation on the equipment, buildings and constructions from the system of ISU "TOIR".
8. Интеграция with the GIS "Zulu" it is also development of OTR-2000 company. In the market of implementation of EAM-systems and Maximo Asset Management in particular there are similar projects on integration into GIS – systems, however with the GIS "Zulu" (the Russian system) of analogs of implementation was not. As a result of integration solutions the user can not only position and select assets using visually user-friendly interface of the GIS "Zulu", but also further make tracking of the current influences on the card.
9. Интеграция with the system of class APCS of Win CC 7.0 regarding information transfer on the counters (sensor) installed on the equipment will allow to implement RCM (Reliability-Centered Maintenance) – management model processes of a MRO on the basis of meter readings, i.e. will allow to prevent failure of the equipment being based according to its current utilization properties.

Completion of works on the agreement was the Fourth stage (November-December, 2010) of the project during which the complex offer on further development and improvement of a system in different areas was prepared.

According to this offer the Customer defined for himself the most priority areas and the job schedule for 2011 – the fifth stage was made.

For implementation of the fifth stage (2011) the supplementary agreement was signed. The fifth stage was devoted to implementation of new functionality. Within the Fifth stage large-scale work on formation of standard process charts of carrying out planned impacts on assets is begun. According to methodology on each standard subject of the qualifier of an asset it is required to create standard process charts by all types of planned influences (KR, SR, TP, TO, etc.). Except direct creation of process charts in 2011 were developed and "became attached" to technology to cards of the estimate. In this direction the integration solution with the Grand estimate PC is improved and the base on quotations in ISU "TOIR" is created that allows already at a stage of advance and annual planning more precisely to plan the amounts of repairs. Works will be continued in 2012. For ensuring new technical requirements on planning process and trackings of influences increased functionality of ISU "TOIR". The document flow of approval of annual diagrams of repairs as the main, and ancillary equipment in a system, mechanisms of calculation and control of the planned funds for repair are added and also the tool for selection of objects of repair according to the expanded list of criteria appeared (for example is implemented: a priority, the index of a status, a meeting of assets, failure probability, etc.) – i.e. the assets recommended for adding in the diagram of repairs. For the purpose of the most complete implementation of requirements two applications "Collection of Plans of a MRO" and "Plans of a MRO" are created. Due to 2011 new technical requirements which arose during process of tracking of influences, using the developed Correction of Work Assignment and Packet of Corrections of Work Assignments applications, functionality regarding adjustment of the approved annual plan MRO is implemented.

Development 3 and 4 levels of the qualifier of defects is complete. Since 2009 were used only the two first a hierarchy level of the qualifier of defects (a class of defect and a problem) filled by operational personnel at registration of defect. But the complete analysis requires accounting of the reason of defect and what measures were taken at its elimination to exclude repeated emergence of defect and at emergence to take an optimal measure of elimination.

Completion of a system regarding creation of the reference book of technology connected equipment is executed. This task is directly connected with the developed Magazine of Requests application and in essence is continuation of the subject of an output of the equipment under control of the system operator touched in the application in repair. Implementation of functionality of ISU "TOIR" on collecting and the analysis of operational indicators of assets (Counters) allowed to begin works on information storage about technical condition of assets for the purpose of further implementation of techniques according to current and forecasting of future state of an asset and carrying out the technical and economic analysis.

One of project deliverables of implementation of ISU "TOIR" was understanding that the implemented classical EAM system (ISU "TOIR" based on IBM MaximoAsset Management) does not allow to answer all questions facing company management and branches when planning and carrying out a MRO. For example, what loss will be suffered by the company if repairs of this asset are not made, or not the complete volume of repair work or when there comes the optimal term of carrying out repair in terms of reliability, profits and security will be executed.

For the answer to these and similar questions to JSC Kazan Combined Heat and Power Plant 1 in 2011 together with AMS LLC company (contractor) the pilot project on application of a technique of maintenance on reliability level started (RCM - Reliability Centred Maintenance) the Core of methodology of RCM is exact and careful collection of data on the available assets. Practical experience of many companies shows that effective implementation of a technique is impossible without IT – tools therefore the methodology gained broad development in the systems of the class RCM. At present different options of implementation of RCM are considered. The OTR-2000 LLC company submitted the offer on this subject. Any the decision on implementation of works on implementation of RCM of methodology development of ISU "TOIR" will be continued. For 2012 a number of areas, such as process charts, planning \tracking of influences, loading of acts of the performed works are defined, etc. which require further study and work are already conducted. It is taken also cognizance of offers of OTR-2000 LLC on implementation of Warning system.