Simulation and implementation of Computerized Maintenance Management System (CMMS)

Transcription

1 1 Simulation and implementation of Computerized Maintenance Management System (CMMS) A. K. Meghelli M. A. Ghernaout Manufacturing Engineering Laboratory of Tlemcen (MELT) Abou-Bekr Belkaid University B. P. N 119 Tlemcen, Algeria EOLE, Abou-Bekr Belkaid University B. P. N 119 Tlemcen, Algeria Abstract-- The computerized Maintenance Management System (CMMS) allows a better maintenance organization of an enterprise service. Management becomes easier and more simple. This ensures the sustainability of equipment and provides a good quality of work. [1] This project consists of the implementation of Coswin 7i software in an important Algerian company s subsidiary of transportation of goods to increase efficiency of maintenance service and to guarantee reliability and availability of truck s; this will imply accumulated gains of money and time. To reach the success of the project, implementation of a CMMS requires a thorough analysis of needs, definition of objectives, and a careful preparation of the actors and the accession of all the staff. Index Terms-- CMMS, Maintenance, Coswin 7i, Arena. - Financial - Technical - Human There are several ways to organize the actions of maintenance for maximum availability of the equipment at minimum cost. The maintenance types are represented in fig. 1,. [4] Fig. 1. The types of maintenance 1. INTRODUCTION The CMMS or Computerized Maintenance Management System is a maintenance tool widely used in the industry. It improves the organization of the maintenance service, management becomes more simple and easy, and it ensures the sustainability of equipment and guarantees a real quality of work. It is a powerful tool that engages the company into a real politics of maintenance. [2] The difficulty for the company wishing to upgrade to a CMMS is to make a choice that will exactly cover its needs. This choice will be followed by an implementation of the CMMS project which will have to take various aspects for the success of the implementation. To ensure the success of the implementation of the CMMS; an implementation approach must be rigorously followed to facilitate the integration of this new computer tool to the internal organization of the company. 2. MAINTENANCE Maintenance is: "Set of all technical, administrative, and management actions, during the cycle of life of property, intended to maintain or restore in a State in which it can perform the required function." (NF EN 13306) [3] Maintenance services must define their objectives to match their company s policy. Goals can affect all aspects of the management with details of deadline: [4] 3. MAINTENANCE PROCEDURE To keep a traceability of interventions, the company has implemented a procedure fig. 2, which will enable improved administrative management of repairs to enrich the history for the good conduct of future interventions. [5] No Repair End Establish an exit ticket from the store Begin Maintenance needs Creating a service request Creating a repair order Part s needs Yes Yes Fig. 2. Maintenance procedure Part available? No a request for supply Receive parts and bill

2 2 The maintenance is done on all park trucks of the company which has several types of vehicles and equipment (see table 1). [5] Type Number Tractor 113 Tray trucks 73 skip 74 truck 10 TABLE 1. Park trucks 4. COMPUTIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS) A CMMS usually consists of hardware solution and a software package that allows an organization to manage the maintenance of equipment and facilities. Use of a CMMS package should improve productivity, lower overall operating costs, and store valuable information about maintenance functions in an organization. The CMMS consists of a database (historical) which is fed by the maintenance staff. Interventions are implemented in memory for some equipment (date, time past, speaking, hardware replaced, etc...). [6] A. Objective of the CMMS To stay within a general framework, the CMMS can be a tool for decision support, the benefits are potentially significant, include: [2] - Control the costs to maintain the facilities. - The sustainability of equipments - Optimize technical and human maintenance means. - Control the preparation of interventions, their planning and their costs. - Optimize the management of the stock of spare parts to reduce the value of the stock and maintain availability of facilities. - Identify the technical facilities and document them. - Reliable installations by the analysis of the return of experience formalized and capitalized, by the decision and the submission of action plans. B. Approach to the implementation of the CMMS The first step in a process of establishment of a CMMS is to identify and quantify the issues of the undertaking concerned. This phase must be preceded by an audit of the company maintenance function, carried out internally or by an external consultant. Fig. 3, traces the different stages of implementation of a CMMS in an organization. 5. Specifications Fig. 3. Steps of implementation of the CMMS The objective of the project is based on the software s implementation but also compared with the former maintenance procedure, in order to see the advantages of the CMMS as well as the benefits brought to the company. After having studied in detail the offer of the software market, the company must transcribe in a book loads its needs and requirements of which will need to position the different publishers that will receive the tender. So the project is to make the study of the existing, then to implement the software selected following the same existing procedure. A. Needs and requirements The approach of needs analysis and the precise definition of the requirements is based on a series of interviews and meetings conducted in company with the different players concerned: directors, computer specialists, users, external consultant. We defined the needs that have triggered this approach of maintenance as follows: - Poor management of spare parts stock. - An anarchic maintenance management. - A long wait before repair. - A bad organization of preventive maintenance. - Unnecessary costs in the current management of maintenance. - An exorbitant cost of stock. B. Evaluation of needs The needs assessment is done by interviews and meetings with responsible to define the objectives. A seminar bringing the various managers helps to explain what imply different indicators and the need for collaboration between the various services to set for example: [7] - Orders for subcontracting and regulatory requirements in terms of security. - The TSR (synthetic performance rate) to measure the productivity of the equipment. - Implementing a provision of equipment for preventive maintenance. - The distribution of responsibilities between logistics and maintenance.

3 3 Following this seminar will be defined: - The general planning of the project - The geographical perimeter - The organizational perimeter - The expected edge tables. C. Expected objectives After you define the needs, objectives should be set to make the right choice of the software that satisfy the expectations of the company, the expected objectives are: - Saving in time on the repair of equipment and any maintenance procedure. - A better organization of maintenance. - Keep the history of the interventions carried out. - Reduction of stock. - A better control of costs. - Give a sense of responsibility to the staff - Ensure the continued existence of equipments. 7. ANALYSIS AND COMPARISON In order to assess the effects of the implementation of the CMMS, maintenance procedure has been implemented in a simulation program using Rockwell Software "ARENA". The principle of simulation is to reproduce the maintenance procedure Fig. 2,, by inserting time treatment and time transfer between the concerned. For the number of intervention by month, fig. 5, traces the history of the first seven months of 2009 and we can deduce an average to be able to represent it with a law of probability. D. Choice of software After the comparison of software available on the market, the software that we have chosen is "coswin 7i" because it fulfills all the conditions and requirements of the company. Its ease of use and its reputation with other companies "coswin 7i" users put it among the leaders of the CMMS market. 6. IMPLEMENTATION The establishment of a maintenance management system needs necessarily a rational organization of maintenance service, either at the level of the structure or policies level. This part is to develop better management of maintenance whether approach: create folders machines and records of the history, management of corrective and preventive interventions, study of the causes of failures and preventive planning. The CMMS system is usually built in a modular way to separate the targeted treatments; these modules are organized as shown in fig. 4,. Fig. 5. Numbers of repair order (jan-july 2009) For the classical procedure of maintenance, data are taken from the history of interventions recorded in the subsidiary. As to the CMMS, data are deducted approximately following the objectives expected and set by the company. Fig. 6, represents the implemented model, either the classic or for the CMMS maintenance procedure, thus we can assess the effects from the results of the simulation of the two systems, the data will be analyzed and interpreted successively to define and determine performance that can bring the CMMS on our System. Fig. 4. The modules of the CMMS Fig. 6. Simulation model The completed model fig. 7, is simulated over a period of one month with 10 replications. And the data corresponding to the two simulated systems are represented in table 2.

4 4 e Fig. 7. Model Arena Arrival (Intervention request) Time treatment Classical procedure CMMS Norm (30,15) Norm (60,60) (Technique reception) 30 min 5 min (Technique reception chef atelier) Time treatment 5 min 5 sec (Foreman) 60 min 5 min (Foreman repair) 5 min 5 sec (Foreman Store) 3 min 5 sec Answer storeman 30 min 5 min Rate of non-avaibility of parts 30% 10% Supplying Disc (0.4,10,0.6,15,0.8, 20,1.0,30) TABLE 2. Data of simulation Norm (7,3)

5 5 First, the comparison will be on the repair order number created per intervention conducted and finalized. Fig. 8, shows the results. Fig. 8. Comparison between input/output We can see that a significant number of requests are not processed for the classical procedure; but with the CMMS all the interventions have been met. Thus it can calculate the rate of quality of each procedure as follows: - Real production: Numbers of input products (including rejected products) - Rejected production: Quantity of products having not finished to repair. For the calculation of the rate of quality, we will take the average value of 10 replications: Classical CMMS = 0,8437 = 84,37% = 0,9735 = 97,35% "ARENA" software allows us to calculate the cumulative mean time of stay of each entity in the system. The purpose of the CMMS is to decrease this duration as minimum as possible in order to deliver outstanding trucks as soon as possible. The simulation results are shown in fig. 9,. In the graph, we can see that the duration of immobilization of gear with classical maintenance is much larger than that of the GMAO, and this implies a loss of time and money for the company. 8. CONCLUSION The maintenance function has been one of the last functions of the company, to benefit from the contributions of the computer tool, that is to say how the road travelled since the implementation of the first computer systems maintenance in the 1980s was sown with obstacles. What is commonly called Computerized of Maintenance management System (CMMS), but should instead call the computer-enhanced maintenance management is not a novelty but the number of failures is almost as important as the number of successes. In the design and implementation of such project, it must be be careful to not succumb to some ideas which tend to believe for example that the computer can solve all problems. Just remember that if it can help to solve, technical problems or problems of management, it has never been in a position to solve the organizational or managerial difficulties. Implementation of the CMMS gave good results in a simulation with software "ARENA". However this study remains theoretical and it is for the company to integrate this tool by involving staff and by exploiting the database of interventions history that will become bigger and bigger; and the benefits of CMMS will appears in the time. The Total Productive Maintenance (TPM) refers to a strategy which aims to improve the actual availability of the equipment. Despite the presence of the word maintenance in the TPM expression, this strategy is much broader than a simple maintenance action. [8] Thanks This work was done in collaboration with the subsidiary MTM (Metidji Transport de Marchandise) of the METIDJI group, I wish to express my sincere thanks. References [1] A. CHAMAR, Abderrahim OUADDI, «La réingénierie du service maintenance, et la mise en place d une application GMAO», Ecole national des sciences, Agadir, [2] Association Française des Ingénieurs et responsable de Maintenance, «Guide National de la maintenance», AFIM, [3] Norme Française, «Maintenance Industrielle», Fonction Maintenance, AFNOR. [4] INGEXPERT, «Conseils, accompagnement du management de la maintenance industrielle, tertiaire, BTP, transport et biomédicale», Ingexpert International, Octobre [5] A.K MEGHELLI, «Mise en place d un système de gestion de maintenance assistée par ordinateur pour la filiale MTM du groupe Metidji», Université de Tlemcen, [6] MJIDILA, «Gestion de la maintenance», OFPPT, Maroc, Fig. 9. Length of stay in the system [7] J. P. VERNIER, «Pratique de la maintenance industrielle», les référentiels DUNOD, Juin [8] Y. LE CAZ, «GMAO», Directeur de Triskel Consulting.