Software product of Liman-Tech company
Maintenance and repair of equipment (MRO)
Equipment maintenance methods differ in cost and efficiency. At the same time, they can be combined in one enterprise.
- -1-Monitoring
The process of monitoring the operation and technical condition of equipment on the production line, in order to detect and prevent possible failures and breakdowns.
It can be performed in various ways, including visual inspection, measurement of equipment operation parameters (for example, temperature, pressure, rotation speed), analysis of audio signals, monitoring of electrical parameters, etc.
- -2-Diagnostics
The process of determining the technical condition of equipment by analyzing data collected during the monitoring of its operation.
Diagnostics can be performed both in manual mode, when operators check the operation of equipment, and in automatic mode, when specialized programs and systems for monitoring and diagnostics of equipment are used.
- -3-Predictive diagnostics
Analysis of a large amount of equipment operation data, in order to predict possible failures and malfunctions in the operation of equipment in the future.
Predictive diagnostics, that is, the search for dependencies and correlations between various parameters of equipment operation and possible malfunctions in its operation, allows you to respond to problems before they occur.
Maintenance and repair tactics (MRO)
There are several maintenance and repair tactics available
Advantages:
Disadvantages:
- Maximum resource usage
- Minimal costs
Disadvantages:
- Limited applicability: The Operation-to-failure MRO model can only be applied in cases where it is possible to estimate the time to failure of equipment based on statistical data on its past use. If there is no such data or it is limited, the model may not be applicable.
- Non-accounting of external factors: The MRO model Operation to failure does not take into account the influence of external factors, such as changes in operating conditions, the environment, etc. Therefore, if these factors significantly affect the operation of the equipment, the model may give inaccurate results.
- Need for data availability: To apply the MRO Operation to Failure model, it is necessary to have a sufficient amount of data on the previous operation of the equipment. If the data is insufficient or of poor quality, the model may produce inaccurate results.\
- Probability estimation required: The MRO model Operation to failure requires an assessment of the probabilities associated with equipment failure, which can be a complex and time-consuming process.
- Inability to account for complex systems: The Operation-to-failure MRO model may not be applicable for complex systems, such as technological processes, where the causes of equipment failure may be related to various factors, including human factors.
Advantages:
Disadvantages:
- The probability of accidents is clear
Disadvantages:
- Need to replace equipment. If the equipment is not replaced, but only repaired after a failure, this may lead to the need for frequent and expensive repairs, as well as equipment downtime.
- Inefficient use of resources. This method does not allow you to use equipment resources at the maximum level, as the equipment may fail earlier than planned.
- Need for spare parts. If spare parts are not stored in a warehouse, this can lead to delays in the repair of equipment, as well as loss of time and money.
Advantages:
Disadvantages:
- Save money. Funds are allocated only for the restoration of really broken parts, which reduces the cost of spare parts and car repairs.
- Increase the intervals between repairs. The frequency of repairs depends directly on the failure of the equipment.
Disadvantages:
- Possible downtime. Repairs are made only after a breakdown, which can lead to losses for the company.
- Increased risk of an accident. If the equipment is not serviced regularly, it can negatively affect the safety of personnel and the reputation of the enterprise.
Advantages:
Disadvantages:
- Reducing the risk of accidents: A proactive approach allows you to identify and fix potential equipment problems before they lead to an emergency.
- Cost reduction: Proactive MRO allows you to replace worn parts and prevent failures at an early stage, which reduces the cost of repair and replacement of equipment.
- Increase efficiency: Proactive MRO allows you to increase equipment productivity and reduce downtime by replacing worn parts, preventive MRO, and eliminating other potential maintenance problems.
Disadvantages:
- High costs. A proactive approach to MRO requires significant expenditures on regular inspections and inspections of equipment, which may be impractical and economically unprofitable for some enterprises.
- Unpredictability. Even with regular inspections and inspections, there may be cases when equipment malfunctions occur unexpectedly and cannot be prevented.
- Difficulty in evaluating the effectiveness of the program. A proactive approach to MRO can be difficult to assess in terms of project effectiveness.
How to choose MRO tactics
What questions should be answered when choosing MRO tactics:
1
What is the criticality of the equipment for the production process and what consequences will arise if it fails?
2
What is the probability of hardware failure and what are the most likely causes of failures?
3
What are the resources (time, financial, human) and capabilities of the enterprise for carrying out various types of MRO?
4
What MRO methods and tools are best suited for this equipment?
5
What conditions and requirements are imposed on the operation of the equipment (for example, frequency of operation, environment, technological features of production) and what types of MRO will best cope with these conditions?
6
What are the long-term implications (including economic ones) of various MRO options?
Implementation of MRO using the Atlas IIoT-platform
Using the MRO system at a modern enterprise is an important element of improving the quality of production and the company's profit.
01
Digitalization of MRO
The most effective measure is MRO automation as such. The purpose of such automation is to::
- Objective monitoring of the equipment condition.
- Accurate calculation of equipment maintenance and repair costs.
- Monitoring the implementation of maintenance actions.
02
Implementation of equipment maintenance methodology
After MRO digitalization, the enterprise can start objective and economically justified work on the implementation of complex technical solutions.
- 1Installing sensors on data acquisition equipmentThe sensors can measure various parameters such as temperature, vibration, vibration level, pressure, etc.
- 2Collecting data from sensors and sending it to the serverThis can be done using special IIoT devices that connect to the hardware and transmit data to the cloud platform.
- 3Processing data on the serverThe collected data can be processed and analyzed in the cloud, using machine learning algorithms and other data analysis methods.
- 4Automatic creation of MRO requestsIf the system detects that the equipment requires MRO, it can automatically create a MRO request, which is sent to the project management system.
- 5Monitoring the implementation of MRO requestsThe Atlas IIoT platform can monitor the implementation of MRO applications to ensure that they are executed in accordance with the requirements.
- 6Analysis of MRO performanceAfter performing MRO, the Atlas IIoT platform can analyze the data to determine how efficiently the MRO was performed and identify opportunities for improving the process.
Example
At the same time, technologies can help all parties in the development process today.
- A log of completed maintenance operations is kept on the site, instructions are stored, and work orders are issued.
- Spare parts are debited in the warehouse, defective items are returned, stock is stored, something is damaged or lost.
- The planning department puts in the budget for the expenditure plan as last year \ + inflation, +just in case, \ + it is necessary to replace 3 nodes.
- "The accounting department debits hours, pays bills, buys spare parts, and so on."
- The administration sees this activity as an expense line in the budget.
At the same time, technologies can help all parties in the development process today.
- For the site, we can schedule work in the form of electronic forms, enter routine operations there, and plan the work in the best way. Fill in the logs, send a warning about a particular repair to your phone or email.
- The system will check whether a routine operation has been performed based on ' s telemetry.
- In the warehouse, materials will be laid out for easy access in accordance with the order of shipment, the system will tell you where the necessary nomenclature was stored, and warn you about the expiration date of the product. The warehouse management system (WMS - warehouse management system, link to the MES Atlas) can help you here.
- The planning department will receive information about which piece of equipment costs how much in operation, and how this cost changes. It will help you decide whether to replace a particular element. It will provide an automatic Feasibility Study.
- The accounting department will be able to assess the effectiveness of the work of divisions, will be able to effectively influence the company's expenses, and make objective decisions.