Sterlitamak Caustic soda: automation of service MRO module TORO of Galaktika

The JSC Kaustik enterprise continues program implementation of improvement of service of maintenance and repair of the equipment. The program is developed by TOIR Consult company and includes several stages which accomplishment will allow to organize and optimize gradually management of a MRO, using modern approaches and techniques.

Implementation

Practically all repair work on Caustic soda is carried out by own forces, there are production capacities on production and repair of spare parts and the capital technology equipment, the total quantity of repair and service staff makes about 2000 persons. For the successful solution of the arising tasks of service it is necessary to see the broad and authentic picture on all stages of hardware maintenance. At the moment for management of repairs separate programs are used: on drawing up estimate documentation and process charts, on cost accounting of works, on creation of need for material resources. Their use solves a part of problems of planning of a MRO, but does not allow to tie works to objects of repair. Accounting of actual costs in the available tools of the used programs does not allow to monitor accomplishment of each repair order and to trace communication with an object.

To transparency

Data of information in a single system of an ACS of a MRO with filling by its relevant database on the equipment and standards will allow to organize in a complex works, to create and prove costs, to keep transparent account, to obtain analytical data, to plan objectively.

Terms and dates

Program implementation is calculated till 2011 for pilot workshops and included: choice of an ACS of a MRO, creation of the database of the equipment and development of standards, development of business management of service MRO, automation. Further it is going to scale the project on other workshops in 2011.

The project is begun in April, 2010. Within the program specialists develop the conceptual solution on automation of service MRO, and the choice of an ACS of a MRO is made. At the enterprise the ERP system Galaktika is used, the decision to cover the MRO area the module TORO of the same system was made. At the enterprise the working groups on setup of a system and data collection for loading are created.

Now it is developed by terms of reference on process automation of maintaining the normative reference information, accounting of operational and technical performances, the MRO ACS model into which the database of the equipment of pilot workshops is loaded is developed, business processes of management of the normative reference information and managements of technical condition of the equipment are implemented, the problem of accounting of defects of the equipment is solved, interface to a control system of a condition of equipment of Honeywell is developed, instructions of users for maintaining the regulatory and reference information, accounting of operational and technical performances are prepared, user training of pilot workshops is provided, there is an active purchase of licenses. Works and on other directions are conducted: work planning on a MRO and accounting of accomplishment of a MRO.

The first stage - results

At the first stage data of information in a single system of a MRO with formation of the relevant database on the equipment and standards are made. It is connected with the fact that at the moment at the enterprise for planning and accounting of repairs separate and different programs are used: on drawing up estimate documentation and process charts, on cost accounting of works, on creation of need for material resources. Their use solves a part of problems of planning of a MRO, but does not allow to tie works to objects of repair. Accounting of actual costs in the available tools of the used programs does not allow to monitor accomplishment of each repair order and to trace communication with an object.

Creation of a uniform ACS of a MRO allowed to organize in a complex works, to create and prove costs, to keep transparent account, to obtain analytical data, to plan objectively. In 2011 it is going to scale the project on other workshops.

Expectations

According to forecasts of the project manager from TOIR Consult Mikhail Gukovsky, the first effects of automation in pilot workshops will be already in the nearest future gained. Project implementation takes place successfully, in particular, thanks to highly qualified specialists of the working group. An important factor of successful project implementation is direct support of the CEO of JSC Kaustik of An Han Doc and the top management of the enterprise and also participation in the project of the deputy chief engineer for capital construction and repairs Sergey Evgenyevich Podtsepnyak that allowed to organize work of the specialists of the plant having direct subordination.