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8/14/2019 Computers in Maintenance
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COMPUTERS
IN
MAINTENANCE
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Introduction
Systematic maintenance planning ---temporary stoppages and shutdowns
Online monitoring --- performance ischecked at regular intervals.
FMS --- change of a broken tool isautomatically done with the help ofprogram provided in the computer system.
Artificial intelligence --- operationsperformed by the robots.
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Computer MaintenanceSystem Development of a database.
Analysis of past records if available.
Development of maintenanceschedules.
Availability of maintenance materials.
Feedback control system.
Project management.
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Job Card System
To record the maintenance workcarried out or the work to be done.
Plant code.
Equipment code. Job code.
Nature of the jobs.
Time of initialization of the card.
Start time of the job. Finish time of the job.
Man hours spent and so forth.
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Job Card Procedure
Job list received from control office or job planning office
Job cards are prepared and issued for every activity.
Job cards placed in loading board/rack against names of menallocated or supervisor for preventive maintenance and other
jobs. Completed job cards checked by issuing supervisor.
Notes made for corrective works required and fresh jobs issuedand placed in the loading board/rack.
Job list signed and summary of manpower completed.
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Inventory Control
Maintenance work always suffers due tonon-availability of spare parts.
Forecasting spare parts and otherrelevant matters can be improved bythe use of computers.
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Inventory Control
What Is It??? Inventory control means keeping track of
your stock
Knowing how much was sold and how muchis left
Lets you know when to order more fuel
Lets you keep records of losses and gains Gives you consumption rates of high demand
and low demand
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Inventory Control
HOW DO I KEEP INVENTORY??? By using inventory data sheets
Daily Readings
Daily inventory balance record
Monthly Summary
Regular tank dipping
Regular meter reading
D il R di
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Daily Readings Product
Month Year
Readings Sales Readings Sales Readings Sales Readings SalesDip
cm.
Inventroy
litres
Water Dip
cm.
Dip
cm.
Inventroy
litres
Water Dip
cm.
1
2
34
5
6
7
8
9
10
11
1213
14
15
16
17
18
19
20
2122
23
24
25
26
27
28
29
3031
Total
Physical
InventoryDay
Total
Meter
Sales
Tank 1 Tank 2Pump 1 Pump 2 Pump 3 Pump 4
This is were information collected from meter
totals and tank dips are added and recorded.
D il I t B l R d
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Daily Inventory Balance Record Product
Month Year
1 2 3 4 5 6 7
Opening Physical
Inventory
Deliveries Meter Sales Inventory Should Be Physical Inventory Variation Today Variation This
Month
1
2
34
5
6
7
8
9
10
11
1213
14
15
16
17
18
19
20
2122
23
24
25
26
27
28
29
3031
TOTALS
Day
Balance sheet is were information is calculated to
determine losses and gains from daily sales. This is a
very important part of fuel management it will give
you important records of sales (this is inventorycontrol).
M thl S
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Month
Total
Sales
Variation
for Month% Loss
Total
Sales
Variation
for Month% Loss
Total
Sales
Variation
for Month% Loss
Monthly Summary
Product Product
Storage Capacity
Product
Storage CapacityStorage Capacity
This is were we record our calculated losses and
gains for every individual month. This sheet is
used for the years sales report. Will give yousales of individual months. Record keeping is a
important method of tracking your inventory.
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Maintenance MaterialPlanning It is possible to know the precise
material requirements in advance andtherefore the procurement process of
quality products can be initiated well intime.
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Feedback system
The reports from the computer programcan be matched with the actual jobs tofind out any deficiency.
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Use Of Network Methods
Detailed networks showing the time foreach activity can be drawn up inconsultation with the maintenance
personnel.
The completion time of each
maintenance job can be easilycalculated to help planners to make themaintenance schedules.
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Maintenance Cost System
The month-wise details of cost ofmaintenance in respect of each plantcan be prepared indicating labor cost,
material cost and overheadexpenditure.
The actual cost is then compared withthe budgeted cost.
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Spare Parts LifeMonitoring System Spares repeatability in various
machines indicating the performance ofsuch spare parts.
Comparisons of the actual life with theestimated life of the spare parts.
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Spare Parts TrackingSystem The total time required to rectify abreakdown of a machine is the sumtotal of the times required for each of
the following operations.
Time to identify the cause of the failure.
Time to determine the requirement of spareparts.
Time to procure the spare parts.
Time to rectify the failure.
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Reports that can be maintained by theuse of computers,
A complete list of breakdowns with reasons, forall equipment, on a weekly/monthly/yearlybasis.
Repetitive kinds of breakdown, indicating the
frequency of failures. Mean time between failures and the expected
repair time, equipment wise. Spare parts repeatability in various machines
with their performance in each machine. New spare parts life monitoring.
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Maintenance InformationSystem Decision making information
Identify problems Develop solutions Take corrective actions
Control the actions Measure the performance
Administrative information Route data reports
Open work order listings Preventive maintenance inspections
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The Information In Respect OfMaintenance Functions Can Be
Collected At Various Levels Unit Level Required items of information are listed out for computerization.
Information about breakdowns must be collected. Idle time costs of equipment.
Material cost. Labor cost.
Aggregate Level Compilation of information.
Information collected is presented in the form ofmonthly/quarterly/annual reports.
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Computer Simulation InMaintenance Forecasting can be done with the help of a
computer using real life data, knowing thepattern of failures (ie. Distribution) the desireddata can be simulated.
So breakdown and repair time data of eachcomponent of an equipment need to be carefullyanalyzed for establishing the following
Breakdown distribution Breakdown period Distribution of length of the time.
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Maintenance DecisionMaking TPS (Transactions Processing Systems) have looked at records of
components, spare parts, fixtures and tools as inputs andconsumption statements and maintenance accounts as outputs.
Other information:
Equipment conditions History of failure Direct cost of maintenance Inventory values and material movements Man-hours spent on maintenance Overtime paid, usage of other facilities made Performance of the maintenance workforce Reliability and maintainability of equipment and maintenance cost
per unit of production.
From these database, maintenance reports can be generated for equipment control, work, control, craftperformance, maintenance performance, over time, delay in work.
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Expert Systems
These are the computer programs builtfor commercial applications using theprogramming techniques of artificial
intelligence, especially those techniquesdeveloped for problem- solving.
Medical diagnostics.
Electronic fault finding.
Mineral prospecting.
Condition monitoring.
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