"Light technologies" automated management of repairs

On February 29, 2016 company "1C:" Announced the first BIT system implementation of management of repairs and hardware maintenance in Light Technologies company. In a basis the software solution "1C: TMAR Technology maintenance and repairs of equipment".

Implementation perspective

In Light Technologies company at the time of the beginning of the project almost all accounting and managerial repair operations of the equipment were executed in spreadsheets. Employees manually planned repair and the cost accounting for them, analyzed hardware failures, optimized budgets on service and repair, developed maintenance strategy.

Office of Light Technologies company (2013)

But because of a gap between business needs and functionality of the used instruments of accounting and management:

• results often were false
• costs for repair work excessively high,
• planning by insufficiently effective:
  • the equipment could stand idle waiting for repair that was wrapped for the enterprise in loss of rates of production and finance.

Specialists of repair services had no online access to information on technical means, supplies, spare parts and personnel resources, necessary for repair. The majority of repairs was initiated only upon the output of the equipment out of operation. On drawing up in the manual mode of diagrams of scheduled preventive maintenance too much time left: for example, the annual diagram formed two and a half weeks.

In the company the double entry accounting of stock balance and component parts for repair was kept. The staff of repair services kept account in spreadsheets, and accountants and financiers – in the 1C: Manufacturing Enterprise Management system. To one accounting nomenclature there could correspond 30 positions in tables of repairmen, there were difficulties with determination of actual balances in a warehouse. In such situation the accuracy of accounting was insufficient, and, at need emergence under repair, component parts necessary for this purpose could be absent.

For change of current situation the system of repair and hardware maintenance for increase in efficiency of planning of actions, increase in accuracy of accounting of stock balance and calculation of materials requirements and component parts, acceleration of reaction of repair personnel to abnormal incidents and timely providing specialists with all information on the forthcoming repair was required. It was necessary to adjust also efficiency analysis of repairs, to accelerate creation of working schedules, to get rid of the double entry accounting.

Work progress

As the information system operating in the company is created to the 1C: Enterprise platform, seamless integration of "1C: TMAR Technology maintenance and repairs of equipment" with implemented before 1C: Manufacturing Enterprise Management became the most acceptable solution. As the contractor of the project the company " is selected by 1C: The first BIT".

In six months processes in the divisions participating in activities for providing a production process are automated:

• department of supply,
• instrumental department,
• treasury
• financial and economic service,
• accounting,
• production,
• service of the chief mechanical engineer
• service of the chief power engineer.

The automated jobs – 20.

Implementation result

• The database, uniform for all divisions, containing the unrolled and reliable information about the equipment, technologies of repair, their planned dates is created. Structuring these data accelerated search of necessary documentation for 50%.
• The system of the normative reference information of repair services is unified – now it is uniform for the integrated systems of 1C and contains names of units and groups of materials and also rules of collecting of material for the subsequent analysis. It helped to organize operational accounting of all economic transactions connected with repairs. Accounting accuracy increased, need of the double entry accounting is excluded.
• Automatic collecting and the analysis of statistics on such cases is adjusted. On the basis of the hardware documentation and its actual operation a system automatically considers wear of the equipment and builds diagrams of scheduled preventive maintenance. In diagrams frequency and planned costs for all production equipment in the long term from one month to ten years is defined. Besides, a system quickly adjusts an order of creation of diagrams according to the standards approved in the company. Time of scheduling of monthly scheduled preventive maintenance decreased from two days to an hour, and annual – from 2.5 weeks to 4 days. The number of abnormal repairs at the enterprise decreased by 20%.
• Requests for scheduled preventive maintenance are created automatically on the basis of the schedule. On the basis of any electronic requests for repair a system creates and sends purchase orders of necessary spare parts to service of supply. It provides timely holding planned repair actions and reduces labor input of document creation. Besides, a system analyzes efficiency of operations on service and repairs of the equipment that allows to organize them more effectively.
• Operational accounting of spare parts in warehouses is organized. A system helps to control stock balance and as soon as their quantity approaches insurance and minimum admissible volumes – announces managers the need for the order. It reduced cases of shortage of spare parts at damage.
• Downtime of the equipment waiting for repair was reduced that became possible due to integration into the system of the module for the operational SMS notification of staff of repair services about the facts of fault of the equipment. It increased the speed of response of specialists to incidents by 30%.

Top management of our company became the customer of the implemented system. Ample opportunities of the analysis, planning and flexible management by resources of the enterprise are necessary for owners, the management and managers who are responsible for business development. For us as large production company, risk minimization, connected with a production cycle is extremely important, and they in many respects are defined by a condition of equipment and quality of a system of repair and service. We consider that the choice made for benefit of the solution "1C: TMAR Technology maintenance and repairs of equipment" and experts "by 1C: The first BIT", is successful and corresponds to our strategic plans. Mikhail Kudinov, development director and to business technologies of Light Technologies company