Asset Optimizing Solutions

8/2/2019 Asset Optimizing Solutions

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Asset Optimization

Solutions


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Asset Optimization Solutions

Will Help to identify and Improve

the true Potential of

existing Plant and Machinery


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MESManufac turingExecution System


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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

Business Concerns related to Production


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ERP

MESField

Controls

The MES Overview


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MES System

Machine StoppageData Options

Data File Counter Data File HMI P.B. Panel

ProductionData Options

PLC in case ofH/W Interfaces

OR OR OR

System Architecture


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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


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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


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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 !!!


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Asset Maintenance


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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

Business Concerns related to Maintenance


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Prodn.Divn. 3

Factory

Prodn.Divn. 1

Prodn.Divn. 2

Section 1 Section 2

Machine 1 Machine 2

AttachedDocuments

4 LevelMachineBreakup

SpecificSpares

Instruments& Gauges

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

JobsAffecting

Production

Jobs NotAffecting

Production

&Work

ManagementThe

Factory


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WorkManagement

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

&

Man Power Spares

Internal External

ConsumableRecyclable

OrRepairable

The Fault Tree

Fault Nature

Fault Code

Cause

Cause 1

Cause 2

ResourceManagement


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The FTM Solution focuses on

Improving Production Uptime - By monitoring % Breakdown,

MTBF & MTTR

Plant Health & Operating Costs

Machine-wise Maintenance Cost - By getting Spares andManpower cost

Effective Spares Management

Effective Repairs Management Track the Recycling of Spares

Root

Cause

Failure Analysis by eliminating

repetitive failures


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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


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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 !!!


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Contact Information

Werardt Systemss Pvt Ltd

Pune, India

Phone : 91-20-25285256, 25285257

Website : http://www.werardt.com

email: [email protected]