Irkutsk Oil Company solved a problem of equipment downtimes, having saved 40% of the budget

2019: Results of system learning "1S:TOIR"

On June 27, 2019 the company "Desnol Soft" reported that Irkutsk Oil Company (INK) summed up the results of use management systems for fixed assets and assets "1S:TOIR". Thoughtful and consecutive work brought results: for the last 2 years Irkutsk oil the company reached economic effect which exceeds the average predicted value.

"For 2 years of use 1CMRO":" the coefficient of technical readiness of the pumping equipment grew from 65% to 98%, coefficient of technical readiness of the compressor equipment — from 45% to 99%. It means that we practically solved a problem of idle times. Besides, the analysis of statistics received from a system did not allow to inflate the planned budget on equipment procurements — economy made 40%", noted Vasily Voronin, the chief mechanical engineer of Irkutsk Oil Company

As of June, 2019 a system continues to develop, increasing functionality and scale.

"As the mature system of the class EAM (Enterprise Asset Management), "1S:TOIR" can give the companies coordinated management by the capital tangible assets, maintenance and repairs (MRO), the logistics (L), warehouse stocks and also finance, personnel and documents (in the field of a MRO). The system business mission — to guarantee transparency of planned and actual costs: The customer not only sees where it is possible to save, he understands how to make expenses minimum sufficient, without losing performance", noted Alexander Klimenko, head 1S:TOIR in Desnol Soft company

The implementation project "1S:TOIR" in INK was under construction according to the following scheme:

1. inspection
2. development of technical specifications
3. creation of the database of the equipment and standards of a pilot zone (certification)
4. creation of the database of the equipment and standards (certification)
5. adaptation of standard functionality
6. trial operation on a pilot object OPI (oil preparation installation)
7. expansion of functionality of a system
8. expansion of the database of the equipment
9. replication of the solution
10. input "1S:TOIR" in commercial operation

In INK at the time of the beginning of the project there were over 30 production facilities and more than 24 main types of the equipment: mechanical, power, instrumentation and automated control systems and APCS. It was necessary to transfer information on the equipment stored on diverse carriers to a system. On separate productions account was kept in xls-tables, were used MS Word and records by hand. It was necessary to standardize huge amount of data, created by employees with the different level of engineering training and computer literacy — masters of installations, mechanics, power engineering specialists, instrumentation and automated control systems engineers, etc.

"Process of normalization of data on start of the project is extremely important. Without it we could not move further. Certification — the base of productive management further, its result should be the code of exact information on what the company owns. Therefore we involved the non-staff specialist in processing and consolidation of data who owing to experience saw a task in the long term, on several stages forward, and helped us to avoid hard errors on start", noted Natalya Markevich, the leading specialist on a MRO of Irkutsk Oil Company

Collection of information on the first 10,000 items of equipment took 3 months. As a result the mass of separate paper and electronic documents was deleted from the internal turnover of the company. The cleaned data were entered in the Excel template, then package loading entered them into system "1S:TOIR". In the amount for 4 years (2014–2018) nearly 42,000 items of equipment are entered into the system.

Formation of base of the equipment is not exhausted by certification (digitization of technical data sheets), the main task — creation of a hierarchical structure of objects of repair. All processes in system "1S:TOIR" rely on it. Sorting and building of taxonomies of objects of repair in base lasted about 3 months, in general formation of base of objects of repair and base of standards on pilot section of production took about 8 months.

For June, 2019 2 types of hierarchy are provided in database "1S:TOIR" used in INK: on a technology position and as the equipment. At all levels of a hierarchical structure in electronic passports of the equipment it is possible to attach any documents concerning this or that object of repair. For example, it is possible to attach to object of oil installation also the technology installation diagram in general, and the technology scheme of inclusion of a specific vessel on the specific production site. The scanned passports of the equipment, certificates of conformity, other allowing documentation — everything is stored in a system and quickly taken if necessary.

"1S:TOIR" helps us to undergo scheduled inspections. It would be required to scan earlier the huge volume of paper documents (their quantity is measured by kilograms), to distract for this purpose personnel on all objects, to equip all divisions multifunction printers is an enormous expense of time and resources. According to the results of the project we bring to paper any documents from a system on a centralized basis using the mechanism of batch print", noted Natalya Markevich, the leading specialist on a MRO of Irkutsk Oil Company

As the enterprise of the extracting industry, INK bears the increased responsibility for effective management of risks in the field of labor protection, industrial environmental safety. With respect thereto in the company the integrated system of management in the field of environmental safety and labor safety and health protection is introduced. The Technical policy is also accepted and works in ensuring reliability of production processes. Accident prevention, accidents and readiness for localization of their effects for INK — basic need. All supply available of the company is divided into 4 security levels, for each level there are the regulations of investigation.

What can the management system for maintenance and repairs of the equipment for risk reduction give? Functionality for reliability augmentation. "1S:TOIR" it was adapted for investigation of failures taking into account classification of the equipment by security.

"Within security policy we accepted the concept "equipment categorization". Categories reflect different extent of influence of failures: a) on financial losses, b) on ecology, c) on reputation of the company. We developed methodology of assessment of this influence and appropriated categories to all tangible assets. It allows to place priorities of repair work and to appoint the administrative level of investigation of failures", noted Vasily Voronin, the chief mechanical engineer of Irkutsk Oil Company

Based on a risks assessment matrix, the categorization facilitates planning in the short term, for month or quarter. In the situation changing the normal course of things or limiting resources — from unscheduled repair before change of the legislation — the choice of a priority helps to build a priority of works: what needs to be made instantly and that it is possible to postpone to the next period with minimum risks.

Accumulation and the analysis of statistics of failures in "1S:TOIR" also helps to make the long-term decisions connected with reliability of the equipment. Failure is not enough to be eliminated, it is necessary to understand how not to allow it from now on.

Long-term partnership of the enterprise with developer company of IT solution yields qualitative result for both parties — the hidden reserves of this or that solution jointly come to light, business needs improve software products.

"We understood that investigation of hardware failures — very powerful statistical tool for management of reliability. Also understood that it it is possible and it is necessary to develop. With respect thereto Desnol Soft developed for us additional functionality for failure logging and formation of the act of technical investigation. Failure logging — one of the first implemented blocks, it does not depend on standards, planning and completeness of the database, but allows to accumulate statistics at once", noted Vasily Voronin, the chief mechanical engineer of Irkutsk Oil Company

The functionality "tightens" from a system all information volume on object of repair: its localization, the place in hierarchies (subordination), keyword parameters, data on the previous surveys and repairs. A system starts counting of a downtime. Registering breakdown, the employee uses specially created qualifier of failures by types of the equipment — consistently answering questions. Thus all necessary data for technical investigation (a failure mode, a type of defect, the defect reason, the root reason) gather quickly, it is not necessary to describe each case separately. Any schemes and explanatory documents can be attached to the act.

As of June, 2019 in "1S:TOIR" about 600 employees of INK, from them 62 curators work. Curators are responsible for hierarchy of the database of the equipment, approval of documents and maintaining reference books (types of defects, types of failures and others). Users with high activity — about 100 for one watch, the others address a system periodically. Training of employees in work with a system happened in several stages: employees of pilot section studied at a stage of input of a system in trial operation, at input in commercial operation – all users, during emergence of new functionality training was provided in addition.

During the project the management system for repairs was integrated into a management structure by the enterprise. Specialists of Desnol Soft integrated "1S:TOIR" about "1C:Enterprise 8. MDM Management of the normative reference information", "1C:Enterprise 8. MTS Logistics", "1C: Accounting 8 PROF" and internal portal of the company.

"We carried out integration with the majority of systems only on the second year of use of a system. Also we consider it the reasonable solution. At first it is worth debugging direct functionality of processes of a MRO — database maintenance of the equipment, planning and accounting of works. When it surely earns, it is possible to move further. In 2019 we already easily do in a system all necessary, all processes are mastered. Plus we expand functionality of a system from the moment of its mastering in 2016, together with Desnol Soft we improve planning mechanisms", noted Natalya Markevich, the leading specialist on a MRO of Irkutsk Oil Company

2016: System implementation "1S:TOIR"

From 2014 to 2016 Irkutsk Oil Company carried out the IT system implementation project for process optimization of repair and hardware maintenance "1S:TOIR" in cooperation with Desnol Soft — developer company of the solution.