Kazanorgsintez and ITPS have completed a project to implement the M&R Information Center

2022: Creation of M&R Information Center

Specialists of PJSC Kazanorgsintez (a major producer and exporter of polyethylene in Russia) in partnership with the ITPS group of companies completed the project to create the Maintenance and Repair Information Center, with the help of which key processes of planning and management of maintenance and repairs were automated and electronic certification of equipment was provided. This was reported by ITPS on April 04, 2022. The implementation of the project allowed the enterprise to reduce labor costs and lay the technological basis for the future transition of the company to a qualitatively different model of M&R management based on integrated analytics and forecasting.

The main goal of the project is to increase the economic efficiency of the M&R unit at an enterprise with a large fleet of equipment and a high cost of downtime. As a key idea for updating the M&R management processes, ITPS specialists proposed to consolidate all data sources, models of long-term and operational calendar plans, resource plan models and MTO models into a single IT solution that ensures the consolidation of all data and actions for planning and managing the block and the ability to work in a single information window mode.

The M&R management information center includes a set of four program modules: "Digital model of the production asset," "Digital model of integrated calendar and resource planning and management of M&R," "Information center of metrological support management" and "Information center of dynamic equipment management." The latter has also been integrated with the MES-System for Dynamic Equipment Operating Time Data Collection to ensure that maintenance and maintenance are scheduled for actual operating time. The created decision provides management of the park of the equipment of PJSC Kazanorgsintez which contains more than 50,000 units of measuring instruments and industrial control system, more than 80,000 units of the capital and service equipment, more than 10,000 technical places (process units, units etc.). As a result of the project, M&R specialists received a convenient functional tool that allows them to work faster with standard transactions and documents (orders, process instructions, acceptance lists, etc.). Staff functional responsibilities are built as a single end-to-end process on all planning horizons - from annual to daily. Intuitive interfaces make the work of specialists more comfortable and productive. At the same time, the staff is exempt from the need to delve into the intricacies of working with IT systems when planning and working in M&R.

The innovative development of the M&R unit is one of the key tasks of our organization, focused on obtaining new market advantages through the digitalization of operational and production processes. The deployed information modules provide us with additional capabilities for planning and managing the M&R unit, enabling us to make the most of existing enterprise resource management tools. The implemented project is an important step for the planned transition of the company to a qualitatively new model of M&R process management, based on assessments of equipment reliability, forecasting failures and taking preventive measures to ensure the continuity of the production process and slow down the natural wear and tear of the equipment, commented on the chief engineer of PJSC Kazanorgsintez Rafael Safarov.

Digitalization of M&R planning and management processes is a reliable protection against unplanned losses resulting from equipment breakdowns. The experience of Kazanorgsintez PJSC convincingly proves that it is possible to achieve significant savings if you switch from point automation to the integrated integration of both the M&R process itself and the associated MTO management processes, cost, finance, etc. Our team successfully copes with this task by creating M&R Information Centers for large industrial customers, stressed the head of ITPS Leonid Tikhomirov.