Minudobreniya (1C:Enterprise 8. TOIR Equipment Repair and Maintenance Management)

2022: Digitalization of material asset management processes at one of the largest chemical enterprises in Russia, JSC Minudobreniya

350 workplaces were automated. At the stage of certification, 99,930 repair facilities were included in the 1S:TOIR, more than 100,000 documents were created at the stage of pilot operation.

IT- company Desnol Soft"," the developer of the system, 1S:TOIR automated maintenance and repair processes at one of the largest chemical enterprises of the country JSC "." Mineral fertilizers System: 1CTOIR KORP with, integrated , and. 1C:ERP 1S:ZUP APCS Now the company can analyze the causes of downtime and malfunctions, deal with downtime, there is a justification for planning maintenance and repair costs and a complete information information about the availability of materials in the warehouse.

Automation results

As a result of the implementation of the KORP 1S:TOIR, JSC "Minudobreniya" received a "live" database of equipment with agreed standards (materials and labor costs) for repair work, with the possibility of accumulating statistics on the state of the equipment. The result is a reduction in the time to search for information on repair objects, obtaining reports on unscheduled repairs and shutdowns, and the formation of a reasonable need for material and labor resources for repairs in the context of units and equipment.

1. The base of standards with material costs is formed, the demand for materials is formed on the basis of WEP schedules. On the test circuits, a check-up of integration was carried out according to the full cycle:

• Loading of materials from the Enterprise Resource Management Master System (1C:ERP CU)
• indication of materials and equipment in the repair schedule;
• generation of demand for materials based on the schedule of WEP;
• unloading the request for consumption to the adjacent IE (1C:ERP CU);
• development according to the request in the adjacent IE (1C:ERP IC).

2. Analysis of the root causes of defects is carried out, management decisions are made on its basis. Monthly distribution of the report on the identified defects to the management.

The following tasks are implemented:

• registration of defects, analysis of the causes of equipment failures and reporting for management decision-making;
• planning standards have been formed. the timing of operations was selectively measured, which makes it possible to make realistic, reasonable work plans;
• The budget for M&R is based on work plans (including on the basis of WEP), work experience. There is a schedule of major repairs, equipment maintenance.

3. A unified asset base has appeared (for the enterprise, in the context of workshops). The search for information on the equipment, its maintenance history is simplified as much as possible.

• The receipt of: the most completed data documentation from the IE, the history of equipment repairs, attachment of various kinds files to the cards of repair objects (drawings, diagrams, manufacturer's passports, etc.) was ensured, this result was achieved due to the adaptation of the system to the requirements of JSC Minudobreniya.
• Loading of printed forms of WEP schedules, work permits, OR passports, equipment nomenclature, certificates and other repair documentation is implemented.

Economic impact of Desnol Soft's 1S:TOIR CORP implementation project

• reduction of labor costs in subdivisions to find information on the composition of equipment and the history of its repairs and maintenance: 25%
• Faster management reporting: 22%
• acceleration of receipt of regulated reporting: 15%
• Order processing acceleration: 10%
• Decrease in inventory: 1%
• Reduction in material resources costs: 1%
• reduction in production costs: 5%
• Reduced operating and administrative costs: 10%
• increase in inventory turnover: 2%
• productivity growth in production: 3%
• 1% reduction in downtime
• 2% Reduction in Order Execution/Service Delivery Times

It became possible for us to analyze the causes of downtime and malfunctions, followed by the formation of corrective measures, which ultimately leads to a decrease in the percentage of equipment downtime, to receive up-to-date information on the repair of equipment. We have reasonable planning of maintenance and repair costs and the ability to reasonably justify the number of repair personnel, as well as the optimization of warehouse stocks and the purchase of materials and spare parts through clear control of their use, in real time there is always up-to-date and complete information about warehouse balances and materials and spare parts released for repairs. noted Deputy Chief Engineer for Maintenance and Repair of JSC "Minudobreniya," Alexander Viktorovich Pavlov.