Tops Consulting: MRO

Scope

The solution is intended for the large capital productive enterprises for which questions of maintenance of the equipment in working order are the most relevant and also can be used for the contract organizations rendering services in repair.

"TOPS Consulting: The MRO" based on Microsoft Dynamics AH can be used in all industries and supports work as average, and the large distributed companies with several thousand at the same time working users. Special attention was paid to implementation of features of planning of repairs of large machines and units with complex functional couplings. Planning of service and accounting of difficult extended objects, such as pipelines of different function and transmission lines is supported that is a necessary condition of automation of large enterprises with complex circuits of production processes.

Among the clients using the solution such companies as JSC SIBECO, JSC Kaluzhsky dvigatel (KADVI), Fanplit, Unitile and others.

Main objectives of implementing solution

Predictability and reliability of operation of the equipment. It is a key task to which solution the main efforts of repair divisions are directed. To solve it, it is necessary to have the complete information about the equipment, beginning from passport data and operating conditions and finishing with the history of the executed repairs.

Performance monitoring of use of resources. The solution helps to answer a question what efforts reach accomplishment of the plan of repairs? Those resources which are available for what reasons there are failures in operation of the equipment what leads to a delay of accomplishment of repairs are how effectively used? Answers to these questions allow to find areas for improvements.

Objective risks assessment. Planning repairs and work of repair divisions, it is important to estimate possible risks objectively. What will be if to move repair in time or not to select the budget for it? How will the production schedule change if to appoint repair to a certain period? The solution gives the chance to estimate risks in a complex, taking into account different parameters that helps to make the weighed and reasoned decisions.

Minimization of operating costs. At the expense of competently constructed and effective plan of repairs readiness of the equipment increases, the fund of working time increases that finally leads to decrease in operating costs.

Based on researches, implementation of management of a MRO yields the following results:

• Reduction of equipment downtimes – for 10% - 15%
• Transparency of investments into maintenance and repairs
• A possibility of economy up to 15–30% of current costs for a MRO
• Reduction of overtime works – for 20%
• Prolongation of life of the equipment – for 5% - 10%
• Accurate organization of repair service:

1. Complete and operational information about a condition of equipment
2. Automation of planning taking into account priority of the equipment and repairs
3. Approval of plans of production
4. the Complete information about activity of division

The main sources of cost reduction at automation of a MRO

Key functionality of the solution

Management of duration of idle times under repair:

• optimization of plans of a MRO with the minimum finding of the equipment under repair, the approved work planning and resources for decrease in number of prolongation of repairs;
• accounting of the status of the performed works allows to control execution of diagrams, to trace performance of transactions during an equipment stop, to reveal discrepancies of planned and actual duration of works;
• maintaining electronic register of defects and subsequent their analysis;
• accounting of an operating time of periodically used equipment and automatic planning of a MRO taking into account an operating time;
• solution integration with the diagnostic systems allows to adjust between-repairs cycles and duration of repairs.

Management of structure of the operated equipment:

• accumulation and data analysis about costs for a MRO with a binding to a specific item of equipment;
• on the basis of the data accumulated in the MRO system the decision on a stop of the equipment and its unplanned output in repair can be made.

Cost management on a MRO:

• formation of costs for a MRO by an item of equipment / a production line / production division;
• the analysis of the reasons of discrepancies of labor input of works for planned values thanks to storage of history of works;
• gain of control of discrepancies in inventory and repair control, the analysis planned and actual data on expenditure of Inventories thanks to communication of the solution with warehouse data;
• automatic purchase planning of spare parts taking into account warehouse and safety stocks that reduces cases of neediness of repair work of required materials;
• tracking and analysis of history of vendor interaction of Inventories.

Reliability of the equipment:

• planning and accounting of all operations on inspection of the equipment, reflection of results and their analysis;
• planning of repairs, upgrades, replacements of nodes on each item of equipment;
• automation of accounting of an operating time and registration of defects allows to lower labor costs and influence of a human factor;
• automation of orders allows to estimate amount of works for the present day in advance and to prepare beforehand for these works;
• the automated processing of requests for an equipment output in repair and approval of activity of production and repair personnel;
• accumulation of history of operational parameters and forecasting of use of the equipment;
• tracking of start-up and stops of the equipment in real time.

Principal components of the solution "TOPS Consulting: A MRO" based on Microsoft Dynamics AH

Implementing solution

Solution "TOPS Consulting: The MRO" can be implemented as in a complex, and on separate blocks. For example, for planning of repairs it is necessary to prepare the regulatory base, and for collecting of necessary data first of all it is necessary to adjust accounting of the equipment and the executed repairs. In this case it is possible to begin with the accounting block, and after accumulation of sufficient amount of data to connect the planning block.

Solution "TOPS Consulting: The MRO" can work as as a part of the ERP system of Microsoft Dynamics AX, and to be integrated with other information systems.

The TOPS Consulting company offers several options of cooperation:

• Delivery of the "boxed" solution. This option is most interesting to those companies which already use Microsoft Dynamics AX in the work, and which have own support service.
• Full-scale implementations. In this case implementation takes place together with TOPS Consulting.

You can receive the detailed description of the solution having downloaded White Paper at the link.