Fault Tree Maintenance
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Fault Tree Maintenance - FTM is system for Plant Maintenance Management - Our FTM Software is used by SKF, Cocacola, Cipla, Sandwik, Toyo India and many leading manufacturer - Manages Lifecycle of an asset. FTM can adopt to the day-to-day terminology that you use on the shopfloor! Excellent ready to use reports.
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Fault Tree Maintenance
- 1. Fault Tree Maintenance A presentation by Werardt Systems P Ltd By: Satish Nande satish@werardt.com
- 2. Werardt started its Operations 20+ years ago, Developing Customized Management Solutions & implementing its own software Products in the Industry โฆ The Company has acquired expertise in a wide range of Domains and has been sharing it with its clients. In the process itโs focus is on enhancing and optimizing Business Operations using sound Processes & Implementation methods while doing so. Werardt has a team of around 30 people for Consulting, Development, Implementation & Support About Werardt
- 3. Werardt Offerings Business โข ERP for Manufacturing โข ERP for Distribution โข Supply Chain Management Manufacturing โข CMMS โข RED TAG System โข Instrument Calibration โข OEE Monitoring Technology โข Mobile based Apps for Field Personnel โข Mobility based Enterprise Solutions for Sales & Distribution โข Machine Interfacing & MIS on the lines of IOT
- 4. Some of our Clients
- 5. Manages lifecycle of an asset โฆ โข Historian for Asset Lifecycle โข Define Assets from Subsystems to Component level โข A Help desk for maintenance requests โข Schedule PMโs and track them โข Track manpower Allocation and Utilization โข Track Machine wise consumption of Spares โข Track maintenance inventory โข Track failure modes, MTBF & MTTR โข Maintain history of incidences & replacements โข Comprehensive operations reports โข Comprehensive MIS Reports System Overview
- 6. Unplanned Maintenance Planned Maintenance Spares Historian of Daily Operations Ready to Use Reports & KPIโs The Plant Production Divisions Departments & Sections Equipment or Machines Management Dashboard Alerts & Notifications Resource Utilization Workflow related to Manpower Contract Labor Scheduled Maintenance Utilities System Overview Equipment Classification โ Document Linking โ Resource Planning โ Mobility Enabled Maintenance Cost Monitoring TPM Integration
- 7. Asset Management Spares Failure Modes & Causes Human Resources Vendors Breakdown Maintenance Preventive Maintenance Document Management System The TPM Module Manpower Utilization Repairs Management AMC Schedule Monitoring Miscellaneous Jobs & Tasks Inventory Management Spares Consumption Utility Equip Monitoring Reports Notifications & Alerts The FTM Modules
- 8. 1. Keep-it-Simple Policy to provide a System that is Practical & Easy-to-Use, 2. Pre-Configured System with pre-Canned Reports, 3. We have an Open Interface for Integrating with other systems 4. In-house developed system that has evolved through Value-added Suggestions from its Users, 5. Focusing on Execution in order to make the System successful & sustainable, 6. Work in a step-by-step Phased manner to make the system work smoothly, 7. Build a Roadmap of how we plan to achieve the Objectives using FTM as a tool, 8. FTM can Adapt to day-to-day Terminologies you use on the Shop floor , Our Approach
- 10. โข Current Status of Operations โข Evaluating Resources โข Business Objectives โข Applying Best Practices โข Proposed Solution โข 4M Alignment โข Implementation Roadmap โข Sustainable Approach โข Review Mechanism Consulting โข IT Pre-requisites โข Software Installation โข Database Setup โข User Access Rights โข Master Data Porting โข Deciding Terminologies โข Reports & MIS โข Setting up Notifications Software โข Implementation Plan โข Defining the Core Team โข Plant Structure โข Defining Maint. Teams โข Master Data prep. โข Training to Go-Live โข Understanding Reports โข Support methodology โข Utilization Review Execution Client Engagement
- 11. Equipment Information Sub-Systems Equipment Asset Information Recyclable Spares Spare Part Code Recyclable Spares Spare Part Code Spares Repairs Module Last Maintainable Component Category & Cost Center Documents & Drawings Maintenance Cost User Defined Attributes Equipment Break-upReplacement Schedule
- 12. โข B/D Breakdown Jobs โข PRTL Partial Breakdowns โข OPRT Opportunity Jobs โข SERV Service Jobs โข MISC Miscellaneous Jobs โข PM Preventive Maintenance Jobs โข ABPM Activity Based PM โข REPRS Repairs of Spares โข R/M Reconditioning & Modifications โข โฆ and others W.O.โs with Downtime W.O.โs with Zero Downtime A Pre-Configured System The Fault Tree Fault Code Causes Pre-configured W.O. Types Shift Timing Wise Computations % Breakdown at Section & Machine Level MTBF & MTTR Cost at Section, Machine & W.O. Level Pareto Analysis at Section & Machine Level Pareto Analysis at Machine Breakup Level Ready-to-use KPIโs For every W.O. you can Allocate Manpower either at the start or enter them at closure along with Spares used, if any
- 13. Simple TPM Module The TPM Module Breakdowns Why-Why Analysis Action Report6W2H Machine-Failure Ranking Machine-Subsystem Ranking Machine Subsystem-Failure Ranking Initial Machine Ranking Machine Ranking Criteria Definition Breakdown-Why-Why report Machine Criteria is based on Frequency, Downtime & Spares Cost And you can define multiple Sets to Compare improvements
- 14. Classical PM in FTM W.O. Schedules Frequency Activities Checklists The Frequency or Periodicity can be in โ โข Weeks (Day of the week), โข Days (Date of the month) or even โข Running Hours (if we can build an interface) Breakdown History w.r.t. PM PM Schedules PM Planner (Year or Month wise) PM Checklist (Pending) PM History (Resource usage) PM Reschedule % Deviation Ready-to-use Reports Checklists can also be in the form of EXCEL Templates Equipment (And its Break-up)
- 15. Activity Based PM (ABPM) W.O. Schedule Individual Activity Frequency You can define the Frequency or Periodicity in no. of Days, which can be different for different Activities based on your planning. ABPM Compliance ABPM W.O.โs ABPM Schedule Generation ABPM Schedules ABPM Checklist ABPM Checklist History Ready-to-use Reports You can attach Documents To Schedules & their W.O.โs Equipment (And its Break-up)
- 16. Cost of Maintenance Cost Areas Breakdowns PM All Other W.O.โs Cost Heads Human resources Spares Repairs W.O. wise Spares Consumption Total Spares Consumption Section, Equipment wise Spares Consumption Equipment Cost Report Manpower Analysis Reports Ready-to-use Reports
- 17. TPM Pillar Breakup Kaizens Zishu Hozen (Autonomous) One Point Lesson Training Needs Preventive Maintenance Investigation on Spare Parts Why-Why Analysis Action Reports 6W2H
- 18. 1. Email Notifications against W.O. generation, 2. SMS Alerts against W.O. generation using your SMS Gateway, 3. Dashboards can be Emailed to pre-configured select individuals, 4. Standard Reports can be Emailed to pre-configured select individuals, 5. We can configure more such Email Alerts & Notifications if required, 6. Schedulers will run to automatically import Spares Data in CSV format from pre-defined locations into FTM Database, 7. Schedulers will run to update the Dashboard Data Warehouse daily, Alerts, Notifications & Schedulers
- 19. 1. For field level personnel โ for example to Technicians, 2. They can enter work done details as-and-when they complete a Job, 3. They can get Spares Stock information on-the-Go, 4. They can see attached Drawings and Documents on-the-Go, 5. We can also customize practical Workflows if they will assist the Maintenance team, 6. This would require IT Approval to use Mobile devices in the Company Network, Mobile & TAB based Android Apps Note: You will have to provide your users with the devices and configure them on your Company network so that they can use FTM in a wireless fashion
- 20. Ready-to-Use Reports Section wise Pareto Equipment wise Pareto Dept. wise Distribution MTBF v/s MTTR PM Planner Fault Tree Analysis Machine Failure Ranking
- 21. The FTM Dashboard Generated v/s Closed Job Distribution review Breakdown Repetitiveness Fault Tree Analysis Downtime Analysis Breakdown Analysis