profylax.cz

1. www.profylax.cz Program for planning and maintenance management IVAR a.s. Osvoboditelů 1228/28 410 02 LovosiceMobil : +420 602 450 101 profylax@profylax.cz

2. The program will provide you with • arrangement of all information about the maintanance into a clear database • a comfortable calendar planning of the preventive maintanance with the choice of manual intervention and supplementation • print of work orders and their easy transfer into the already realised maintanance • a complete overview of the realised maintanence (ISO audit!) , repairs and their costs • prints for the ISO audit, statistics of capacity utilization and other prints for the improvement of the maintanance management and planning

3. Characteristic features of the Programme • THE NETWORK version is not limited by the number of users! • PROFYLAX is programmed in the development environment Delphi for the Windows operating system. The operation is therefore standard and intuitive. For data storage we use the NexusDB database, which is an adequate solution of the client/server model proved in many instalations of the attendance systems of Ivar a.s. • PROFYLAX can operate in the local or network version. The instalation is easy and does not necessarily require any implementation assistance. • The access to the program is protected by passwords and access rights of the particular users, which are defined by the administrator. The access rights reach up to particular machines and individual items of the menu. • You can record 5 gradual and an unlimited number of nongradual maintanance to every machine and you can also record profession, workers and material to every maintanance. • There is a possibility of interconnection with the state of spare parts in your ERP system and the additional programming of the specific functions.

4. Log into the Profylax • After the program start there appears the login dialogue, which requires the user name and the password for the access to the program. • After the instalation of PROFYLAX there is implicitly set only 1 user called MASTER without any set password. • After the confirmation of the OK button the program will check the correctness of the entered data for the access. If these data are not right a warning message is displayed.

5. The PROFYLAX administrator should later enter more users, who will have set particular access rights to the program. Here particular users of the program are defined. Type of user – you have the choice to place a new user into the predifined types: Administrator, Foreman, Serviceman, Other1, Other2, …, Other7 If you place the user to a particular type, you give him the access rights which are defined for the particular types of users.

6. The main window of Profylax Main menu Main menu of program: • Machines • Hierarchy (Cost units, Production lines, Locations) • Plan • Maintenance • Diagnostics • Workers • Partners • Store • Purchase • Orders • Reports/ graphs • Param • Administration • Help • Exit

7. 1. Machine/tool card The machine is a basis of the maintanance database. The basic information is stored here. The whole tool card is clearly conceived with the help of tabs, where each tab includes certain integrated information about the machine. Into the tool card you can write everything what you need to know about it. Beside the predefined data you can use the unlimited text note, add a photo or directions for use. In the tool card the particular kinds of machine maintanance are defined: gradual and nongradual, calendar maintanance and also the maintanance according to diagnostics (motohours…). Through the tool card you can access to the plan and history of maintanance and repairs. Tabs of machine card: • Detail • List • Add-in • Ext • Unhierarchy maint. • Repairs • Diagnostics • Reports • Maintenance plan • Made maintenance • MTBF • Spares • Partners • Documents • Photo

8. 1.1 Detail In the Detail tab you enter the basic information about a machine in the form of a form. The Evidence number and Name are mandatory data. Every machine on the tool card can be assigned to one cost center, shutdown point (line) or location. An important part of this machine tab is the definition of the particular gradual maintenance of a machine. In PROFYLAX you can define 5 gradual maintenance for one machine. What is a gradual maintenance? It is a maintenance, where higher maintenance always includes also operation of the lower maintenance.

9. 1.2 List In the List tab there are displayed basic information about the machine in a form of charts The main charts of Profylax can be modified with the help of layout setting.

10. 1.3. List of machines in a hierarchical mode

11. 1.4 Unhierarchy maintenance In the Nongradual maintenance tab there are defined independently repeatedly performed maintenance or single events such as revisions, trainings etc.

12. 1.5 Repairs • In the Repairs tab you fill in particular repairs of the machine. The procedure of the repair entry is following: • repair entry • transfer of the repair into the maintenance plan • record of the repair implementation 1. Repair record on the machine card

13. 2. Move repair to the plan + write repair

14. 3. Write the final repair/maintenance 1.6 Maintenance plan/Maintenance entry In this machine tab there is a set plan of the maintenance of a particular machine. It is possible to change the plan and after the real maintenance implementation you record it.

15. 1.7 Made maintenance The recorded and saved maintenance is already displayed in the Made maintenance tab.

16. 1.8 Reports Here the users enter the defects and events online to a particular machine. After that the report can be adjusted by repair, the Adjust button or just postponed for later.

17. 1.9 Diagnostics Specially for the mills and foundries With the help of a special module you can control the tool and form maintenance according to the number of moldings, castings etc. (a maintenance according to diagnostics). In the daybook you fill in the diagnostics subtracts to the machines or the subtracts are overtaken by the file from the automatic counters. The evidence of machines movement – which tool was attached with which machine (press) and how many lifts has it done, when was it put into the stock or repaired.

18. 1.10 Spares Particular machines are composed of different parts, which themselves are not a subject of the maintenance. Individual parts can be assigned from the material list – from the stock.

19. 1.11 Documents You can attach necessary documents to particular machines (such as instructions, service documents, invoices etc.). These files are not saved directly in the machine database but there is only a reference to such document. Particular documents (word, excel etc.) can be opened and modified directly from the program. It is recommended to set up a directory (for example DOC) on a shared disc where you can save documents connected with particular machines in the database.

20. 1.12 Partners The Partners tab is used to interconnection between particular partners with the machines (e.g. Suppliers of spare parts, servicemen…).

21. 1.13 Photo In the Photo tab you can attach a random photography. It is an informative photo, which helps you with the easier identification of a machine in the card.

22. Locations The definition of machine placement is hierarchical, that is it starts from the highest point of the hierarchy (COMPANY) and subordinate locations are defined under this (e.g. Halls, sectors…). According to the location the serviceman can easily orientate himself in the area of the production hall. Other hierarchical code lists are: Cost Centers and Shutdown points.

23. Reports for all machines Reports to the machines: the operators or setup men can immediately enter the requirements to the maintenance. The maintenance manager has an immediate overview and can gradually attend the reports according to their accomplishment.

24. Planning PROFYLAX on the basis of machine card data you can create a maintenance plan and idle time schedule for selected periods. It will be displayed in the form of calendar or in detail as a table. In terms of planning is maintenance period, period tolerance and finally performed maintenance is essential. Planned actions can be manually moved to other dates and the change is included when planning again. The plan can be printed in various forms and for each action taken work order can be printed too. When starting PROFYLAX will let you know about current maintenance and its timely preparation.

25. Workers It serves to keep records of all workers who are involved in maintenance realization. These entered workers can be assigned to particular types of maintenance, to planned maintenance and especially to completed maintenance records. Moreover, there is code book of professions, which are related to the performed maintenance. Each worker should belong to a certain profession. In terms of maintenance capacity planning, firstly the workload of professions is important, then we can assign workers to work orders.

26. Partners List of partners related to machines (e.g. suppliers of spare parts, service companies, overhauls). Important contacts can be entered here so that they would be available for all, who need them. There is also e-mail and link to web at disposal. Moreover, documents (contracts) can be attached. Partners can be assigned to machines, by selection made from a list on machine card.

27. Made maintenance Complete overview of all performed maintenance + repairs and related costs. Here you can see, how your machines followed the preventive maintenance intervals, what repairs were carried out with particular machines, occurred machine faults, for instance you can immediately find out who conducted the previous maintenance etc. This is also a simple way of providing evidence of maintenance level for ISO audit. The record of performed maintenance is really simple, most often it is just transfer of work order into the form of completed maintenance, all with one click.

28. MTBF, MTTR • Fill the available times and downtime for the required period. • Whenever we have the results in the selected time period: from - to

29. MTBF, MTTR • Calculation by one button - Count • MTBF – Mean-Time-Between-Failure is also a metric for machine performance. It is the inverse of Failure Rate and is thus calculated from the same parameters. It is a meaningful metric for long periods of time but not suitable for daily or weekly monitoring. If there are no breakdowns in a given period, the MTBF for that period is mathematically "undefined." • MTTR - Mean-Time-To-Repair is another simple yet valuable metric for industrial maintenance. It reflects both the severity of breakdowns and the efficacy of repair activities.

30. Store The maintenance stock is usually administered within central stock control. Then, in Profylax you simply keep a code list of selected items and we will just connect Profylax to your stock. If you wish to control maintenance stock directly in Profylax, we have separately licensed module STORE for you. It enables standard stock holding: records of more local stocks, issue receipt, release and transfer notes. When entering performed maintenance, a release note of consumed material assigned to maintenance is automatically created.

31. Orders To make an order spare parts directly in Profylax, we have a separately licensed module ORDERS. This allows APPROVAL, on which the request, demand, and the Purchase Order.

32. Reports / Graphs PROFYLAX offers tens of prints, synoptically listed. The prints are shown in the overview window before the printing starts. Some can be customised by users. Thousands pieces of print output can be filtered according to time period or other criteria. The filters can be predefined and saved, so next time you just select the right one, and you don’t have to enter anything. Graphic form enables Top Ten analyses (Fault rate, expense ratio, idle time interval …)

33. Thank you for your attention and wish you success in your maintenance management Standard for planning and maintenance management Send your questions to the address:  profylax@profylax.cz