Parus Management maintenance and repairs of the equipment

Experience of the customers of "PARUS Corporation" implementing complex systems of management confirms that use of the module "Management of Maintenance and Repair of the Equipment" in a complex with other modules "Management Systems PARUS" allows to increase cost efficiency of operation of the equipment, in particular, except standard results of increase in transparency and efficiency of accounting, to strengthen control and management of activity of the enterprise.

Premises of creation of ISU maintenance and repair of the equipment

• Repair costs and maintenance of the equipment – a considerable component of costs in cost value of products;
• Need for ensuring smooth operation of the equipment, installations, productions;
• Big constructive and technology variety of technical objects, need for condition monitoring of the equipment;
• The large volume of the technical documentation accompanying processes of maintenance and repair;
• The need for concentration and coordination of information on an object, use of information by different technical services in interaction in the course of maintenance and repair;
• Impact of processes of maintenance and repair on indicators of reliability of systems and equipment, labor safety;
• Need for monitoring of repair processes, tracking of a status of repair work, control of terms and qualities of their execution;
• Need for coordination of production and repair processes and processes of supply;
• Need for optimization of spare part inventories and materials.

Continued production requires reliable operation of the equipment. One of tasks of the application is increase in its reliability due to failure prediction, timely TO and repairs. For prevention of emergency situations it is necessary to collect and process data on technical condition of the equipment. It allows to predict hardware failures and to timely execute preventive actions. Application of SCADA of systems for collecting of parameters of the CU helps to reduce influence of a human factor on reliability of the equipment. Determination of strict regulations on execution of works and control of its observance reduces risk of low-quality repair and TO.

Purpose of the module "Management of Maintenance and Repair of the Equipment"

Basic purpose of the application is automation business of processes of management of maintenance and repair of the equipment for the purpose of increase in their cost efficiency.

The module allows to ensure the interconnected functioning of the automated jobs of specialists on production facilities which part the equipment which is subject to maintenance and repair (divisions of management of the chief mechanical engineer, chief power engineer, chief metrologist, an overhaul, etc.) is.

Automated workplaces perform input, storage, processing and issue of the data including set of primary and summary technical and economic indicators.

The module provides interrelation of planning processes, accounting and the analysis of maintenance and repair of the equipment. The autonomous, and being a part of technology chains objects of the enterprise can be objects of repair both.

The list of solvable tasks of ISU based on PARUS-TORUS

Within accounting of structure of the equipment:

• Classification of technical objects;
• Classification of levels of structure of objects;
• Representation of structure of divisions and the equipment in the form of a hierarchical structure;
• Formation of data on objects and their components;
• Coding of objects and their components;
• Maintaining protocol of replacements of components of objects;
• Calculation of service life (resource) of components of objects;
• Calculation of mean value of service life (resource) of components of objects;
• Drawing up reports on the set criteria.

Within time management of work (idle times) of the equipment:

• Scheduling of loading of the equipment;
• Classification of idle times;
• Registration of idle times;
• Determination of operating time (operating time) of objects;
• Analysis of idle times and measure calculation;
• Report generation about idle times on requests.

At assessment of technical condition of the equipment:

• Drawing up object list, subject to diagnosing;
• Formation for the diagnosed components of subjects of the list of diagnostic parameters;
• Determination of regulations of individual diagnosing of components of objects;
• Scheduling of diagnosing of components of objects;
• Registration of extreme values of diagnostic parameters, damages;
• Registration of continuous data of individual and complex diagnosing;
• Calculation of damage level (status) of components of an object;
• Calculation of complete and residual resources of components of an object according to measurements of diagnostic parameter;
• Creation of diagrams of change of diagnostic parameters;
• Object status assessment based on complex diagnosing;
• Registration of parameters of damages of the components replaced at scheduled repairs.

Within control of operation of a production equipment:

• Registration of damages and failures during an interrepair time;
• The analysis of damages and failures during an interrepair time.

At stages of planning of repairs and maintenance:

• Formation of the object lists which are subject to repairs and TO;
• Planning of frequency of TR of separate objects (planning 1 - go about);
• Planning of frequency of KR of separate objects (planning 1 - go about);
• Planning of frequency of TO on object components (planning 1 - go about);
• Planning of TR, KR - drawing up diagrams of repairs of a complex of objects (planning of the 2nd order);
• Planning of TO - drawing up diagrams of TO of a complex of objects (planning of the 2nd order) for all types of objects.

When forming technical documentation:

• Work planning of TP, CP and KP (drawing up repair sheets);
• Drawing up or selection of process charts of repairs and TO;
• Drawing up the sheet of an expense of spare parts and materials on the executed repairs;
• Drawing up tasks for TO.

When providing with spare parts and materials:

Determination of requirement and assessment of stocks:

• Introduction of the database of spare parts and materials;
• Determination of need for spare parts and materials for the planned period;
• Drawing up orders;
• Registration and order processing;
• Assessment of optimum level of regulation of a stock;
• Determination of value of a safety stock;

Purchase management:

• Accounting of purchase orders and production;
• Accounting of agreements with suppliers;

Management of spare parts depot and materials:

• Database maintenance of storage locations of products and materials;
• Arrival registration of products and materials;
• Registration of issue of products and materials;
• Report generation about the current existence of products and materials;
• Registration of the actual expense of spare parts and materials.

During the planning and the cost accounting:

• Planning of the budget (repair stock);
• Cost accounting;
• Drawing up cost statements by the set criteria.

Within management of technical documentation (archive):

• Accounting of documents on objects;
• Accounting of documents on storage locations;
• Accounting of issue and return of documents;
• Document retrieval by their parameters;
• Selection of documents by the set criteria;
• Document handling, the electronic files presented in the form;
• Report generation.

Interaction of the modules "Management Systems PARUS"

The module "Management of TOR" can function as it is autonomous, and in interaction with the modules "Management Systems PARUS" automating other parties of enterprise management.

The interface between an APCS, used at the enterprise, and the "Assessment of Technical Condition of the Equipment" function of the module TORUS will provide automatic registration of diagnostic parameters of the equipment. As a result of processing of parameters assessment of damage level (status), residual and complete service lives (components) can be made.

Interaction with an APCS

The "Assessment of Technical Condition of the Equipment" function of the module TORUS is intended for data recording about the value of diagnostic parameters of components (elements) of the equipment. The interface between SCADA a system and this function will provide automatic registration of diagnostic parameters of the equipment.

As a result of processing of parameters assessment of damage level (status), residual and complete service lives (components) is made.

Depending on a condition of equipment the personnel which are responsible for its repair need to perform certain operations on reduction of the equipment in regulation (routine or unplanned maintenance, repair, additional diagnostics, replacement, etc.). It is also necessary to execute a number of organizational actions, for example, the notification of different services about an equipment stop, formation of an order on repair or TO, the order of spare parts, etc.

Technical documentation on hardware maintenance contains techniques of maintenance, process charts of repair, but for a variety of reasons (removal from production of spare parts, obsolescence of the equipment, change of operating conditions, etc.) documentation can not conform to requirements. Besides, on a number of productions the old equipment on which the regulating documentation lost legal force is used.

The need for accumulation of knowledge of repair and maintenance of the equipment is available. The knowledge management system should allow to accumulate information on technologies and techniques of carrying out TO and repairs, to create new techniques, to analyze information on repair procedures in different cuts.

The knowledge base is created for specific type of the equipment and represents the formalized set of standard actions (process charts) at emergence of standard events possible during operation of the equipment. A set of process charts is defined by the user for type or a specific copy of the equipment. The process chart consists of the list of actions (actions) united in a route and connected among themselves. Unconditional and conditional branches between route points are possible. Conditions of transition can depend on the diagnostic parameters and other conditions set by the user. The choice of this or that process chart is performed automatically and caused by a set of the diagnostic parameters and their values which arrived from SCADA of a system. A set of parameters and their values influencing the choice of the process chart is set on the basis of the regulating documentation, statistical data, etc.

The point of a route of the process chart can have information or managing character. In a point of a route operation can be performed, the additional information is entered, i.e. on a system corrective action is made (for example, an equipment output from operation, change of data about conditions of equipment, etc.)