Computers in Maintenance

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COMPUTERS

IN

MAINTENANCE


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Introduction

Systematic maintenance planning ---temporary stoppages and shutdowns

Online monitoring --- performance ischecked at regular intervals.

FMS --- change of a broken tool isautomatically done with the help ofprogram provided in the computer system.

Artificial intelligence --- operationsperformed by the robots.


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Computer MaintenanceSystem Development of a database.

Analysis of past records if available.

Development of maintenanceschedules.

Availability of maintenance materials.

Feedback control system.

Project management.


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Job Card System

To record the maintenance workcarried out or the work to be done.

Plant code.

Equipment code. Job code.

Nature of the jobs.

Time of initialization of the card.

Start time of the job. Finish time of the job.

Man hours spent and so forth.


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Job Card Procedure

Job list received from control office or job planning office

Job cards are prepared and issued for every activity.

Job cards placed in loading board/rack against names of menallocated or supervisor for preventive maintenance and other

jobs. Completed job cards checked by issuing supervisor.

Notes made for corrective works required and fresh jobs issuedand placed in the loading board/rack.

Job list signed and summary of manpower completed.


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Inventory Control

Maintenance work always suffers due tonon-availability of spare parts.

Forecasting spare parts and otherrelevant matters can be improved bythe use of computers.


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Inventory Control

What Is It??? Inventory control means keeping track of

your stock

Knowing how much was sold and how muchis left

Lets you know when to order more fuel

Lets you keep records of losses and gains Gives you consumption rates of high demand

and low demand


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Inventory Control

HOW DO I KEEP INVENTORY??? By using inventory data sheets

Daily Readings

Daily inventory balance record

Monthly Summary

Regular tank dipping

Regular meter reading

D il R di


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Daily Readings Product

Month Year

Readings Sales Readings Sales Readings Sales Readings SalesDip

cm.

Inventroy

litres

Water Dip

cm.

Dip

cm.

Inventroy

litres

Water Dip

cm.

1

2

34

5

6

7

8

9

10

11

1213

14

15

16

17

18

19

20

2122

23

24

25

26

27

28

29

3031

Total

Physical

InventoryDay

Total

Meter

Sales

Tank 1 Tank 2Pump 1 Pump 2 Pump 3 Pump 4

This is were information collected from meter

totals and tank dips are added and recorded.

D il I t B l R d


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Daily Inventory Balance Record Product

Month Year

1 2 3 4 5 6 7

Opening Physical

Inventory

Deliveries Meter Sales Inventory Should Be Physical Inventory Variation Today Variation This

Month

1

2

34

5

6

7

8

9

10

11

1213

14

15

16

17

18

19

20

2122

23

24

25

26

27

28

29

3031

TOTALS

Day

Balance sheet is were information is calculated to

determine losses and gains from daily sales. This is a

very important part of fuel management it will give

you important records of sales (this is inventorycontrol).

M thl S


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Month

Total

Sales

Variation

for Month% Loss

Total

Sales

Variation

for Month% Loss

Total

Sales

Variation

for Month% Loss

Monthly Summary

Product Product

Storage Capacity

Product

Storage CapacityStorage Capacity

This is were we record our calculated losses and

gains for every individual month. This sheet is

used for the years sales report. Will give yousales of individual months. Record keeping is a

important method of tracking your inventory.


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Maintenance MaterialPlanning It is possible to know the precise

material requirements in advance andtherefore the procurement process of

quality products can be initiated well intime.


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Feedback system

The reports from the computer programcan be matched with the actual jobs tofind out any deficiency.


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Use Of Network Methods

Detailed networks showing the time foreach activity can be drawn up inconsultation with the maintenance

personnel.

The completion time of each

maintenance job can be easilycalculated to help planners to make themaintenance schedules.


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Maintenance Cost System

The month-wise details of cost ofmaintenance in respect of each plantcan be prepared indicating labor cost,

material cost and overheadexpenditure.

The actual cost is then compared withthe budgeted cost.


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Spare Parts LifeMonitoring System Spares repeatability in various

machines indicating the performance ofsuch spare parts.

Comparisons of the actual life with theestimated life of the spare parts.


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Spare Parts TrackingSystem The total time required to rectify abreakdown of a machine is the sumtotal of the times required for each of

the following operations.

Time to identify the cause of the failure.

Time to determine the requirement of spareparts.

Time to procure the spare parts.

Time to rectify the failure.


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Reports that can be maintained by theuse of computers,

A complete list of breakdowns with reasons, forall equipment, on a weekly/monthly/yearlybasis.

Repetitive kinds of breakdown, indicating the

frequency of failures. Mean time between failures and the expected

repair time, equipment wise. Spare parts repeatability in various machines

with their performance in each machine. New spare parts life monitoring.


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Maintenance InformationSystem Decision making information

Identify problems Develop solutions Take corrective actions

Control the actions Measure the performance

Administrative information Route data reports

Open work order listings Preventive maintenance inspections


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The Information In Respect OfMaintenance Functions Can Be

Collected At Various Levels Unit Level Required items of information are listed out for computerization.

Information about breakdowns must be collected. Idle time costs of equipment.

Material cost. Labor cost.

Aggregate Level Compilation of information.

Information collected is presented in the form ofmonthly/quarterly/annual reports.


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Computer Simulation InMaintenance Forecasting can be done with the help of a

computer using real life data, knowing thepattern of failures (ie. Distribution) the desireddata can be simulated.

So breakdown and repair time data of eachcomponent of an equipment need to be carefullyanalyzed for establishing the following

Breakdown distribution Breakdown period Distribution of length of the time.


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Maintenance DecisionMaking TPS (Transactions Processing Systems) have looked at records of

components, spare parts, fixtures and tools as inputs andconsumption statements and maintenance accounts as outputs.

Other information:

Equipment conditions History of failure Direct cost of maintenance Inventory values and material movements Man-hours spent on maintenance Overtime paid, usage of other facilities made Performance of the maintenance workforce Reliability and maintainability of equipment and maintenance cost

per unit of production.

From these database, maintenance reports can be generated for equipment control, work, control, craftperformance, maintenance performance, over time, delay in work.


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Expert Systems

These are the computer programs builtfor commercial applications using theprogramming techniques of artificial

intelligence, especially those techniquesdeveloped for problem- solving.

Medical diagnostics.

Electronic fault finding.

Mineral prospecting.

Condition monitoring.


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Computers in Maintenance

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