REPORT : COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

Group Members :Asad Khan (ME 304)Naveed Ahmad Khan (ME 015)Muhammad Asad Umer (ME 047)Ronald Joseph (ME 068)Muhammad Saad Ali (ME 066)Submitted To :Sir Kashif NoorREPORT : COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

Table of Contents

1.Introduction to CMMS41.1What is CMMS ??41.2History of CMMS51.3Uses of CMMS61.4Who uses CMMS systems ??71.5Importance of CMMS81.6Advantages of CMMS91.7Disadvantages of CMMS101.8Future of CMMS11

2.CMMS and softwares 122.1API Pro122.2Visual Asset Manager122.3FAMS142.4MSTS142.5PlantLog152.6TMA Systems16

3.CMMS and industries173.1Some famous industries using CMMS technology17

Conclusion ...20 References 21

List of Figures

Chapter No. 01:Figure 1.1: Power 10, a powerful and flexible CMMS system4Figure 1.2: Improvement through CMMS8

Chapter No. 02:Figure 2.1: CMMS software12Figure 2.2: API Pro management software13Figure 2.3: Visual asset manager software13Figure 2.4: FAMS software14Figure 2.5: MSTS software15Figure 2.6: PlantLog management software15Figure 2.7: TMA Systems management software16

Chapter no. 03:Figure 3.1: Logo of ASC Inc.17Figure 3.2: Logo of Apex Inc.17Figure 3.3: Logo of Highland plastics Inc.18Figure 3.4: Logo of Reliable tool and Machine Inc.18Figure 3.5: Logo of US Army Corps of Engineers.18Figure 3.6: Logo of USDHS of which USCBP is a sub-department.19Figure 3.7: Logo of Enginetics Aerospace.19Figure 3.8: Logo of Electrolux.19

CHAPTER O1

INTRODUCTION TO CMMS

1.1 What is CMMS ??

CMMS stands for Computerized Maintenance Management System. The main purpose of this system can be described in one sentence as: Know What Work Has Been Done on Your Assets and What it Costs !!

Figure 1.1 : Power 10, a powerful and flexible CMMS systemCMMS are utilized by facilities maintenance organizations to record, manage and communicate their day-to-day operations. The system can provide reports used in managing the organization's resources, preparing facilities key performance indicators (KPIs)/metrics to use in evaluating the effectiveness of the current operations and for making organizational and personnel decisions. In today's maintenance world the CMMS is an essential tool for the modern facilities maintenance organization. Switching from reactive to proactive maintenance extends the life of equipment while reducing the overall operating costs of the maintenance function.Computerized Maintenance Management System (CMMS) is also known as Enterprise Asset Management and Computerized Maintenance Management Information System (CMMIS).A CMMS software package maintains a computer database of information about an organizations maintenance operations, i.e. CMMIS computerized maintenance management information system. This information is intended to help maintenance workers do their jobs more effectively (for example, determining which machines require maintenance and which storerooms contain the spare parts they need) and to help management make informed decisions (for example, calculating the cost of machine breakdown repair versus preventive maintenance for each machine, possibly leading to better allocation of resources). CMMS data may also be used to verify regulatory compliance.CMMS packages may be used by any organization that must perform maintenance on equipment, assets and property. Some CMMS products focus on particular industry sectors (e.g. the maintenance of vehicle fleets or health care facilities). Other products aim to be more general.CMMS packages can produce status reports and documents giving details or summaries of maintenance activities. The more sophisticated the package, the more analysis facilities are available. The CMMS may also generate metrics such as the Facility Condition Index (FCI) to measure effectiveness of asset management.Many CMMS packages can be either web-based, meaning they are hosted by the company selling the product on an outside server, or LAN based, meaning that the company buying the software hosts the product on their own server.CMMS packages are closely related to computer-aided facility management packages (also called facility management software). For the purposes of many organizations, the two are interchangeable.

1.2 History of CMMS :Prior to the computer age, paper records were maintained to track the work. Reports were simple but costly to prepare. With the dawn of the computer age it was recognized that computer software could be used to record work requirements, track the status of the work and analyze the recorded data for managing the work, produce reports and help control costs.Computers are powerful, relatively inexpensive, easy to use, and provide tools to support improved maintenance practices. Tools are available for facility professionals that can manage the planning and day-to-day operations and maintenance activities required for a single facility or a large complex, providing all of the information required to manage the work, the work force, and the costs necessary to generate management reports and historical data.Initially this system was used only by large organizations but is now used by almost all organizations and industries as they have analyzed the importance of this system by comparing their maintenance cost with and without this system.

1.3 Uses of CMMS :

Tracking Work-OrdersMaintenance managers can select equipment with a problem, describe the problem and assign a specific technician to do the work. When the machine is fixed, the responsible technician marks the work-order "complete" and the manager gets notified that the work is done.

Scheduling TasksAs a team starts to schedule preventive maintenance in advance, they need a reliable work calendar. CMMS systems are especially good at scheduling recurring work and sending reminders to the right people. Organized scheduling helps even out the workload for a maintenance team, and makes sure that tasks don't get forgotten.

Recording Asset HistoryMany maintenance teams have to care for assets that are 10, 20, even 30 years old. These machines have a long history of repairs. When a problem comes up, it is always useful to see how this problem was solved last time. In CMMS systems, when repairs are done, they are recorded in the machine's history log and can be viewed again by workers. This saves a lot of time - technicians can rely on past experience to solve problems. CMMS systems can be utilized to keep track of a buildings past struggles, including repetitive repairs of the same piece of machinery and departments that face consistently rising expenses. Many times, when companies tighten their budgets, the first things cut are maintenance activities considered unnecessary.

External Work-RequestsMaintenance teams often have to take a work-request from people outside the team. This can be a request from an assembly line operator who is hearing a strange noise from a drill, or a tenant at an apartment building who is requesting shower repairs. The CMMS is a central place for recording these requests and tracking their completion. CMMS also allows for maintenance tickets to be fulfilled in order of importance. A hospital, for example, could program their CMMS to place top priority on pressing maintenance tickets that involved things like repairing faulty patient monitoring machines or replacing fire alarms to ascertain that these vital requests were taken care of in a timely manner.

Managing InventoryYou might not think about it at first, but maintenance people have to store and manage a lot of inventory: spare parts for machines, and supplies like oil and grease. CMMS systems let the team see how many items are in storage, how many were used in repairs and when new ones need to be ordered. This inventory management ability saves the organization a lot of money, because purchases can be pre-planned (shopping around for savings) instead of done last-minute (paying any price just to have the component now). Storage rooms are haphazardly organized and improperly inventoried, causing havoc when maintenance managers need to locate a specific item. CMMS systems, however, allow managers to automatically reorder parts based upon historical use and demand. The software will also maintain a pre-set budget by comparing the number of partsmaintenance work orderannually to the number actually used, and adjusting inventory needs accordingly.

Audit and CertificationMany CMMS systems keep an unchangeable record of every action, so an asset's maintenance history can be audited. This is useful in case of an accident or insurance claim - an inspector can verify if the proper maintenance was completed on a machine. CMMS systems also keep data in a centralized system, which helps keep "one version of the truth" for ISO certification. By helping keep up regular maintenance of HVAC systems, CMMS systems help with getting LEED certification. At least a few times a year, businesses generally must face safety and code compliance inspections conducted by government and private agencies. CMMS systems, though, can make the experience vastly easier by keeping an automatic repository of all necessary paperwork if the company faces an audit.

1.4 Who uses CMMS ??Just about every kind of industry needs maintenance - and CMMS systems help record and plan that maintenance. There are 4 major types of users for these systems: Production Maintenance - these are companies that make things. They have machines, assembly lines, forklifts and heavy equipment.Facility Maintenance - these are companies that take care of buildings. Apartment buildings, theaters and government buildings all need maintenance, and CMMS systems help them deal with structural, HVAC and water-supply problems.Fleet Maintenance - these are companies that take care of vehicles. Car rental companies, pizza delivery cars and fleets of towing trucks all need to have repairs scheduled and maintenance done. CMMS systems help take care of fleets of mobile vehicles. But, transportation doesn't just mean cars - fleets of ships, city buses and long-haul trucks can all go into a CMMS system.Linear Asset Maintenance - this is a special category of maintenance for companies that have assets that are kilometers long. For example, a city's linear assets are roads and water pipes; a telecom company needs to maintain fiber-optic cabling and energy utility needs to maintain long spans of electrical wiring.

1.5 Importance of CMMS :Computerized maintenance management system (CMMS) is easily the most important key to success for a maintenance systems manager by improving maintenance performance. Once implemented, CMMS systems are quite useful to a vast spectrum of industries.

Figure 1.2 : Improvement through CMMS1.6 Advantages of CMMS :By the implementation of a Computerized Maintenance Management System (CMMS), we can expect these real-world benefits: Less work outages:because it is easy to do preventive maintenance, there are less surprise breakdowns. Eliminates paper-work: Using software for maintenance and facilities management eliminates the need for paperwork and clipboards because the software can be set up to capture information automatically. Furthermore, maintenance personnel can view all information related to work orders on their computers. Therefore, maintenance technicians dont have to search through folders and filing cabinets to find the information they need. Enhance productivity: Maintenance software also provides maintenance technicians with details about the procedures, parts, and tools necessary to perform a job, so they can work without delay or interruption. Reduce downtime:Downtime is costly both in terms of revenue loss and damage to an organizations brand and reputation. When you focus on planned, preventative maintenance, equipment downtime is minimized. Because a CMMS system enables you to regularly maintain structures and assets, they are less prone to breaking down, which means that repair costs are also reduced. Increase safety:Computerized maintenance management software aids organizations in regularly checking and maintaining equipment and meeting safety standards to prevent malfunction and critical failures. This minimizes the loss of work time due to accidents and makes your equipment safer both for operators and the environment. Keep a finger on the pulse of your organization:Increase your understanding of your assets and organization by using thebusiness intelligence dashboardfeature in your CMMS to monitor key performance indicators (KPIs), look at the big picture, and create reports for decision makers. By using a CMMS to analyze historical data and trends, maintenance managers can identify problems areas, like rising costs, low productivity, or constant repairs. Better accountability:you can see if a technician did their work on time, and get alerted when a task is complete. Less overtime:better scheduling of work means that your team isn't sitting idle or working overtime, work can be distributed evenly. Information capture:technicians can record problems and solutions, so this information is in writing - not just in their head. Savings on purchases:inventory planning features give you the time to shop around for spare-time pricing, instead of having to buy in a hurry. Certification & analysis:a full record of assets and performance helps managers analyze energy usage and plan maintenance spend. Ensure compliance with regulatory standards: Maintenance and facilities management systems must often comply with national and international regulatory standards. All maintenance managers face periodic audits or random inspections by regulatory agencies. Maintenance software allows you to demonstrate regulatory compliance and reduce the amount of preparation and paperwork thats required for an audit. Maintenance managers can simply generate reports detailing the maintenance work performed on vital machinery. This makes compliance easily traceable and reduces the risk of noncompliance penalties.

1.7 Disadvantages of CMMS :

Initial cost :

High quality CMMS software can cost a great deal; however, not all companies need the top-notch, ultra-expensive CMMS software, and finding the correct fit for a company can be difficult. Workers must be trained in how the new software works, likewise supervisors must have more training which includes troubleshooting, fixing malfunctions and understanding CMMS error messaging and data, which can cost a lot of money. If workers are not trained, CMMS cannot do its job, keeping the machines from being maintained, resulting in high costs for possible replacements.

Misuse of CMMSCMMS cannot be fully utilized when procedures and policies are not followed by workers. Employees and supervisors alike need to know what is expected from their company and the use of CMMS software and know how to input and retrieve the data needed. Many operators may think that the system software will do everything; however, time and money will be wasted if work procedures such as entering data, retrieving data and updating company information are not aligned with the CMMS software. Untrained workers using the CMMS may end up relying too much on CMMS, hence not understanding the mechanics and maintenance needed.

CMMS Vendor Can Go Out of BusinessMany CMMS software vendors are swarming the market now, and finding a stable vendor may prove to be difficult. If your company invests in specific CMMS software and the CMMS vendor goes out of business, your maintenance investment will cost you money and time for nothing in return. There will be no preventive maintenance support system for your company. Supervisors, workers and employees may also not be up to par regarding manual maintenance because of too much reliance on software.

1.8 Future of CMMS :Modern CMMS companies are focusing on these areas as a direction for future development:

Mobile CMMS ApplicationsBy the nature of the job, maintenance workers spend most of their time outside the office - fixing machines and taking care of buildings. Making the CMMS available right there on their mobile phone is a great benefit. With a mobile interface to the CMMS, the technician can record what they are doing as they are doing it, recording pictures of the work and requesting help onsite.

Easy to Use CMMSMany established CMMS companies make products that are very difficult to use - the interface hasn't changed since the late 1990's, and many exotic features have been added to the product. Newer CMMS companies often try to simplify the maintenance process and to make the software easy to use without needing a thick manual.

Fast CMMS Data EntryThe majorities of CMMS projects that fail fail because it is too difficult and time consuming to enter data into the system. The next frontier in CMMS design is in designing fast ways to enter data into the system. For example, Maintenance Assistant took on this challenge by designing an application called "Spare Time". This program lets a technician enter CMMS data by walking through the facility and taking pictures. A full asset hierarchy can be built in a 2 hour walk through the location.

Web-based CMMS systemsOlder CMMS systems are all based on a downloadable piece of software, which needs to run on a server at the client company. New CMMS companies are mostly focused on providing a private CMMS system for their clients whom runs online. The fact that the CMMS-maker takes care of all the IT, security and backups appeals to many maintenance teams - this hosting model is becoming more popular. CHAPTER 02

CMMS SOFTWARES

Figure 2.1 : CMMS software2.1 API Pro :API PRO is enterprise asset management software and is designed with a unique flexibility enabling it to adapt easily to many industries. Special features have been developed for challenging industries like utilities, food, pharmaceutical industry, automotive and several others. APIPRO is the most flexible Maintenance Management System available on the market. Company focus on flexibility, cost effectiveness and quality requires support from powerful information systems that are based upon standard components that can be tailored and scaled to specific needs, and that integrate seamlessly with other company information systems. APIPRO does all of this and more.

2.2 Visual Asset Manager :

The VAM system offers several key novel differentiating capabilities from competitive tools. Firstly, VAM utilizes a small hand held computer tool to easily enter inspection data, including direct linking of electronic floor plans to photos taken from the site. This on-site data entry capability simplifies the data collection step and reduces the chances of data transcription errors associated with conventional paper based manual practices.

Figure 2.2 : API Pro management software

Figure 2.3 : Visual asset manager software

2.3 FAMS :Fixed Assets Management System (FAMS) is integrated software to keep track of fixed assets. It has covered practically all the modules that a company looks for in a Fixed Asset Management Software. FAMS is the complete software that helps you maintain records of fixed assets. Complete details of each asset including cost, useful life, user, location, department, cost centre etc. can be maintained. Several other dimensions of an asset can be added by creating User Defined Fields.

Figure 2.4 : FAMS software

2.4 MSTS :MSTS (Manufacturing Support Tracking System) has not only been designed for the Maintenance Department to use, but manufacturing personnel as well. Most CMMS systems rely on either one person on a Help Desk who is solely responsible for inputting the work orders or the work orders are created by the maintenance personnel who have performed the work. MSTS is so simple to use that anyone from Operators up to Managers can create the work orders which tends to generate a more detailed request. Whether you are running a proactive or reactive Maintenance Department, or maybe trying to turn your reactive Department into a proactive one, MSTS is for you.

Figure 2.5 : MSTS software

2.5 PlantLog :This is maintenance management software to track virtually every aspect of your facility from virtually anywhere. A new breed of maintenance management software which let the user gets out from under the never ending pile of work orders. PlantLogs intuitive approach lets you customize a workflow to match your specific operational needs.

Figure 2.6 : PlantLog management software2.6 TMA Systems :

For more than twenty years, TMA Systems has been recognized as a world-class provider of advanced Computerized Maintenance Management Systems (CMMS). These software solutions are for organizations that want to effectively manage their assets and streamline their maintenance operations. These leading-edge solutions are a key tool for managers who recognize that maintaining their facility's assets and providing the highest level of service is imperative to meeting the high standards being demanded by their organizations. Most importantly, the information generated by these solutions will provide them with the ability to make better decisions, run operations more efficiently, and achieve the ultimate goal - improve their organizations' financial performance.

Figure 2.7 : TMA Systems management software

CHAPTER 03

CMMS AND INDUSTRIES

3.1 Some famous industries using CMMS Technology:

Air System Components Inc. is a leading manufacturer of air distribution products for commercial, industrial, and residential applications.

Figure 3.1 : Logo of ASC Inc.

Apex Industries, Inc. is a diversified Manufacturer, Distributions and Solutions Company that serves or supplies customers on 6 of the 7 continents of the world. Headquartered out of Moncton, NB, Canada, Apex operates in various business sectors including Aerospace and Defense, Oil and Gas, Mining, Marine and Construction. Capabilities range from the manufacture of aerospace components and aero structures, to complex heavy fabricated and machined oil and gas equipment, to custom metal and detention doors/frames.

Figure 3.2 : Logo of Apex Inc.

Highland Plastics is a customer-focused manufacturer of plastic sheet. HPI works in conjunction with each customer to ensure that every product is tailored to the unique application the part is intended for. Highland can evaluate the application, along with any testing or specification requirements, and recommend a material based on years worth of extrusion experience. We will work with you to develop the most cost effective product to meet the application requirements.

Figure 3.3 : Logo of Highland plastics Inc.

Reliable Tool and Machine Inc. buys, sells and brokers machines Tooling Electrical parts and is full service machinery and tooling dealer.

Figure 3.4 : Logo of Reliable tool and Machine Inc.

US Army Corps of Engineers has approximately 37,000 dedicated Civilians and Soldiers delivering engineering services to customers in more than130 countries worldwide. With environmental sustainability as a guiding principle, our disciplined Corps team is working diligently to strengthen our Nations security by building and maintaining Americas infrastructure and providing military facilities where our service members train, work and live.

Figure 3.5 : Logo of US Army Corps of Engineers

US Customs & Border Protection With more than 60,000 employees, CBP is one of the world's largest law enforcement organizations and is charged withkeeping terrorists and their weapons out of the U.S. while facilitating lawful international travel and trade. As the world's first full-service border entity, CBP takes a comprehensive approach to border management and control, combining customs, immigration, border security, and agricultural protection into one coordinated and supportive activity.

Top of FormBottom of Form

Figure 3.6 : Logo of USDHS of which USCBP is a sub-department

Enginetics Aerospace Founded in 1976 as a manufacturer of prototype parts, Enginetics has grown from five full-time employees into a leading provider of complex metal formed components and fabricated assemblies for the global aerospace industry. With expertise in complex metal forming processes, engineering services, and new product introduction, we have continuously demonstrated our abilities as a best-in-class manufacturer and sought after partner for our impressive list of OEM, Tier I, and government customers.

Figure 3.7 : Logo of Enginetics Aerospace

Electrolux is a leading global, appliance manufacturer, commanding strong positions in all regions, and is the only player that offers complete solutions for both consumers and professional users.

Figure 3.8 : Logo of ElectroluxCONCLUSION

Through the detailed study of Computerized Maintenance Management Systems (CMMS) we finally come to the conclusion that CMMS systems are modern technologies which are improving maintenance systems by reducing the breakdowns and costs related to these breakdowns.These systems are very much helpful in reducing accidental breakdowns through perfect monitoring of machines and assets and by predicting accurately the time for their maintenance. CMMS systems are also good managers of past records. They manage and store past records of an organization, analyze them and predict accurately about the cause and time of maintenance. They also help the maintenance team in maintaining and repairing those assets.CMMS also provides a communication link between the maintenance team and other members of the firm so that any breakdown or failure can be immediately reported and repaired.Thus analyzing these benefits and the reduction in costs, it can be recommended that every organization must have a CMMS system installed if the owner really wants to gain more profit and to let his or her organization become one of the best organizations of the world.

REFERENCES

https://www.facebook.com/UnitedRockProducts http://cmmssolution.wordpress.com/2012/01/31/the-importance-of-cmms/ www.dpsi.com/blog/10-advantages-of-using-computerized-maintenance-management-software/ www.ehow.com/list_6498759_disadvantages-maintenance-management-software-_cmms_.html http://www.wbdg.org/om/cmms.php http://www.fastfacts.co.in/fams.asp http://en.wikipedia.org/wiki/Computerized_maintenance_management_system http://www.cbp.gov/about http://www.maintenanceassistant.com/cmms/ http://power10.co.il/en/ http://www.usace.army.mil/About.aspx http://www.slideshare.net/ebeser/managing-equipment-with-visual-asset-manager http://www.sentineluk.co.uk/ http://www.parkworks.com/about.asp http://www.airsysco.com/ http://www.apexindustries.com/main.php?sec=corp http://www.highlandplasticsinc.com/ http://www.reliabletoolmachine.com/ http://www.enginetics.com/ http://group.electrolux.com/en/category/about/21