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Asset Optimization Solutions

Asset Optimization Solutions. Asset Optimization Solutions. Will Help to identify and Improve the true Potential of existing Plant and Machinery. Business Concerns related to Production. Not getting the desired output from every Production assets due to unplanned Downtime

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Asset Optimization Solutions

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  1. Asset Optimization Solutions

  2. Asset Optimization Solutions Will Help to identify and Improve the true Potential of existing Plant and Machinery

  3. Business Concerns related to Production • Not getting the desired output from every Production assets due • to unplanned Downtime • Discrepancy in Design v/s Actual output from Production assets • Cannot realize full ROI on Investments made in Production assets • Data collected on the Shop floor not helping on proper Analysis to • apply improvement measures • Unexplainable Delivery failures due to lack of authentic data • Availability, Rejection & Productivity not being appropriately • measured so as to arrive at daily OEE across the plant • Figures such as OLE and OPE not available due to lack of correct data • Not able to apply TPM principles to help in CIP (Continuous • Improvement Programs) to optimize on Asset Utilization for Production

  4. The MES Overview ERP Field Controls MES

  5. System Architecture MES System Production Data Options Machine Stoppage Data Options PLC in case of H/W Interfaces OR OR OR Data File Counter Data File HMI P.B. Panel

  6. The MES Solution • A comprehensive Production MIS covering various reports • required for standardization of information outputs • An Integrated System to help in reducing Data • Redundancy and provide Authentic data from the system • on a regular basis • Data can be captured either manually or through • electronic interfaces with the Machines, if possible • A Scalable application considering the future growth of • the Organization making it compatible to TPM ideology

  7. The MES Solution • Will help to save on… • - Time to analyze the daily production data. • - Time to analyze the daily Rejection data • - Time to analyze the daily Production Lost time Data • And will also provide OEE, OLE and OPE figures • Will help to reduce the response time in analyzing the data • and thus lead management in taking timely action wherever • required • Offers data Security at multiple levels of Management • Standardize the reporting system for all the Sections and • Machines throughout the organization

  8. The MES Solution • Store Production Data in a Database Server instead of • discrete files to minimize the risk of Data loss • Objective based Implementation will help to successfully • deploy the system in your Organization • Is closely integrated with our existing FTM System as part of • your daily workflow MES is fast to Deploy & Easy to use !!!

  9. Business Concerns related to Maintenance • Productivity being directly hampered because of Breakdowns • Repetitive problems decreasing the overall efficiency of Machines • A lot of time being spent by Maintenance before Audits due to lack of proper records being maintained • Lack of proper Spares Management increasing cost of Maintenance • Non-compliance to Preventive Maintenance schedules • Not able to correctly quantify planned v/s unplanned maintenance jobs • Doubts in Reliability of all Corrective Maintenance jobs • Not realizing the full potential of TPM philosophy – Kaizens, Jishu Hozen, 5S, etc. not being implemented practically on a long term basis • Not able to set Performance Measurement Benchmarks and targets to improve upon Maintenance operations • Maintenance being demoralized due to criticism by everyone in spite of extra hours being spent in the plant

  10. & Work Management TheFactory Factory Jobs Affecting Production B/D PRTL OPRT SERV PM / ABPM REPRS MISC (User Defined) CB Prodn. Divn. 1 Prodn. Divn. 3 Prodn. Divn. 2 Jobs Not Affecting Production Section 1 Section 2 Machine 1 Machine 2 4 Level Machine Breakup Attached Documents Specific Spares Instruments & Gauges

  11. & Resource Management Work Management The Fault Tree Fault Nature Fault Code Cause Cause 1 Cause 2 B/D PRTL OPRT SERV PM / ABPM REPRS MISC (User Defined) CB Spares Man Power Internal External Recyclable Or Repairable Consumable

  12. The FTM Solution focuses on … • Improving Production Uptime - By monitoring % Breakdown, • MTBF & MTTR • Plant Health & Operating Costs • Machine-wise Maintenance Cost - By getting Spares and • Manpower cost • Effective Spares Management • Effective Repairs Management – Track the Recycling of Spares • Root Cause Failure Analysis by eliminating • repetitive failures

  13. The FTM Solution focuses on … • Developing a Centralized Knowledge Base • Streamlining the Workflow & Quantifying your Work • Improving PM, Proactive Jobs & Condition Monitoring • Optimum Utilization of Resources • Effective & Timely Documentation • Realizing Total Plant Reliability

  14. The FTM Helps to Achieve • RCM - Reliability Centered Maintenance • CBM - Condition Based Maintenance • TBM - Time Based Maintenance • RCFA - Root Cause Failure Analysis • CIP - Continuous Improvement Processes FTM is fast to Deploy & Easy to use !!!

  15. Contact Information Werardt Systemss Pvt Ltd Pune, India Phone : 91-20-25285256, 25285257 Website : http://www.werardt.com email: business@werardt.com

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