On MMK trial operation of a management system for reliability of the equipment started

2020

Start of trial operation of ISU reliability of production assets

In November, 2020 on Magnitogorsk Iron and Steel Works trial operation of the information management system is begun with reliability of production assets. It is created based on the GE Meridium APM software product integrated with a corporate information system of PJSC MMK reported on February 15, 2021 in Meynteks company.

The implementation project of an information system started in the spring of 2020. It became an important stage in the course of the transition to risk-oriented approach in maintenance and repairs begun by the enterprise in 2017. Big preparatory work is during this time carried out: the organization structure of the main service enterprise of Group of MMK – OSK LLC – with selection of functions of reliability and planning is changed; regulating documents – techniques, instructions for management of reliability are developed; training of specialists is provided.

As a pilot zone for project implementation the high-quality workshop and LPTs-5 are selected. Implementation was carried out by the Meynteks command jointly with specialists of the enterprises of Group of MMK – "MMP-Informservice" and "OSK". The considerable volume of work is done: IT- a system is adapted for requirements of the enterprise, flows of integration of Meridium into the module "Repairs" are implemented Oracle EDMS Informix, "Monitoring-2014", training for heads and specialists is provided.

The solution Meridium APM allows to estimate automatically in a complex a ratio of types of repair and service influences, cost of the adjusting and pro-active works, production losses, repair costs, availability and readiness of the equipment. And also to define risks and to distribute resources (both financial, and labor) taking into account criticality of the equipment and acceptable risk level of failures.

Integration of a management system for reliability with a corporate information system of PJSC MMK based on Oracle e-Business Siute V12 (CIS) allowed to move to the following level of ensuring availability of the equipment for accomplishment of the production function, to close a development cycle and preparation of maintenance strategies with its execution and accounting.

The first results give the chance to note effect of transition to management of reliability using an information system:

• increase in effective operating time of the equipment,
• increase in safety of operation of the equipment,
• decrease in planned costs proceeding from the level of risks of a hardware failure, acceptable for business,
• increase in availability of information on a current status of the equipment and prime causes of unplanned failures.

"Having headed for modern asset management strategies, MMK went a long way of transformation of the approaches. Application of the solution GE Meridium is logical continuation of this initiative", – the chief executive of Meynteks LLC Roman Romakhin noted.

In 2021 PJSC MMK, based on results of trial operation, will continue works on development of a system and distribution of the best practices which proved the efficiency on all industrial platform.

Step-by-step project implementation "Improvement of the MRO system of the equipment

On August 7, 2020 it became known that 2 years on Magnitogorsk Iron and Steel Works there is step-by-step accomplishment of the large-scale project "Improvement of the MRO system of the equipment of PJSC MMK. From the moment of project initiation it was clear that it will be long and difficult. It was necessary to improve a lot of things, cardinally to change something, and in some areas to start initiatives from scratch. As well as in any similar project it concerns three key components – processes, technologies and people. In scales of MMK problems of transformation of the MRO system were particularly acute.

Personnel training of the enterprise involved in management processes of a MRO was an initial task. The Meynteks company provided unique training of staff of MMK that allowed to start the next stages of the project more effectively and to speak to all participants of a project team one language.

Transformation of processes under the TOIR advanced reliability-oriented system became the next logical stage. Based on the gained knowledge profile specialists of MMK and OCK developed a number of fundamental documents which formed the basis of the internal standard of MMK on management of reliability and a MRO.

After completion of training of people, formalization and building of business processes need for process automation of performance management and reliability of assets ripened. This area is very exacting to completeness and quality of large volumes of data and also to deep study of business processes of management of reliability. Even having the trained personnel and the business processes built according to business objectives of the company impracticablly effectively to manage data and processes without IT tools. For this reason Magnitogorsk Iron and Steel Works selected the leading solution GE Meridium APM.

Implementing solution only begins. It is supposed that Meynteks as the reliable partner of MMK, will execute implementation of IT solution in scope functional baseline, will execute development of an integration bus between GE Meridium APM and Oracle e-Business Suite v12, will impart knowledge and core competencies to a command of MMK and OCK, and the plant will conduct scaling and replication of GE Meridium APM independently with remote support of a command of Meynteks. It is planned that as a result reliability and efficiency of the equipment of all workshops of Magnitogorsk Iron and Steel Works will be controlled and to raise steadily using the solution GE Meridium APM.