COMPUTERISED MAINTENANCE MANAGEMENT SYSTEMS ROBERT KOSTEK University of Technology and Life Sciences Summary The paper presents programs dedicated to computerised maintenance management systems (CMMS). The main aims of the programs are: effective maintenance of machines, rational asset management, and consequently higher productivity of a company. The programs can be dedicated to particular industry sectors or can be more general, but they contain similar modules. One can find the lists of: assets, resources, preventive maintenance jobs, breakdowns, massages, and documents. The programs can be treated as database systems and messenger programs which aid the analyses of data and exchange of information among staff. Keywords: computerised, maintenance, management, systems 1. Introduction CMMS programs have been inspired by management theories. For instance, Deming's 85/15 rule; 85% of a worker's effectiveness is determined by the system he works within, while only 15% by his own skill [1,2], which inspires to modification of the system. CMMS programs give an opportunity to exchange information and documents among staff quickly, in an electronic form. Moreover, maintenance jobs are well described and illustrated; thus, workers receive legible information. In CMMS programs one can find some ideas of Deming's 14 points [3]. 4 th end the practice of awarding business on the basis of a price tag; the programs have a ranking of suppliers. 5 th improve the system of production and service constantly and forever; improve quality and productivity, and, thus, constantly decrease costs; the programs give an opportunity to find machines which generate the highest costs of maintenance and break-downs. 9 th break down barriers between departments; some of CMMS programs give an opportunity to exchange information and ideas between the departments of a company. 12 th remove barriers that rob an hourly worker of his right to pride of workmanship; the programs give an opportunity to reduce the number of breakdowns. The next important idea in CMMS context is the 80/20 rule, known as The Pareto principle [4,2]. In short, it means, that the maintenance effort should be particularly focused on a small number of the most important machines. In CMMS programs machines are usually in a group created specially for the machines. Finally, financial liquidity of a company can be higher if CMMS programs are applied. The programs give an opportunity to find and reduce overstock of maintenance materials and spare parts by stock level monitoring. Moreover, clear purchase procedures are applied in the programs.
278 POLISH ASSOCIATION FOR KNOWLEDGE MANAGEMENT Series: Studies & Proceedings No. 35, 2010 Purchase procedures and stock level can be supported by operational research, which is a separate issue. 2. CMMS programs MAXIMO is a CMMS program which contains six modules [5]: Maximo Asset Management, Maximo Work Management, Maximo Service Management, Maximo Contract Management, Maximo Materials Management, Maximo Procurement Management. The modules reflect major tasks which are realised within companies. The program is dedicated to large companies where most of the tasks should be computerised. Aretics is a net-based program that has one server and a number of computers connected to the server [6]. If mobile Internet network is applied, then the system can be mobile, which gives an opportunity to apply the system in transport companies, and exchange information online between workers which are outside the company. The program contains the following modules: asset (Fig. 1), human resources, maintenance jobs, stocks, documents, and rapports. The modules are dedicated to managers that are able to analyse data; workers, on the other hand, use a simple program, Aretics T7.Injector, which is a kind of messenger. Aretics T7.Injector informs workers and managers about: work order, breakdowns, rapports of maintenance staff, and the progress of maintenance jobs. Fig. 1. Illustrated lists of machines
Robert Kostek Computerised maintenance management systems 279 Fig. 2. Interface of Aretics T7. Injector General-purpose CMMS programs are: SUR-FAD [2], mp2 [7], Infor EAM [8], and ZMTv2.0 [9]. The programs have similar modules to Aretics; they are focused on: maintenance jobs, asset management, planning jobs, stocks, documents, and rapports. On the other hand, SZEOR v.3.0 is a program dedicated to the maintenance of technical systems like: plants, pipelines and tanks [10]. The program, apart from the aforementioned modules, has modules coupled with: forecasting of service life of a plant and technical inspection. Apart from general-purpose CMMS programs, there are programs dedicated to particular applications. For instance, Golem OEE SuperVisor, and Golem Mini are dedicated to monitoring an automated production line [11]. The programs collect information from measuring sensors and staff about: energy consumption, parameters of a process, down-times, reasons of down-times, and productivity. In this case, down-time, idle time, time of tool exchange, machine time, and processing time are the most important parameters. Received results are finally presented in figures, which aids management. Other programs dedicated to particular applications are programs dedicated to automotive service. They are: Autodata [12], Vivid WorkshopData [13], Info-tech [14], and Moto-Warsztat [15]. The programs contain all the necessary information which aids car maintenance and repair. One can find information about: costs of repair, time of repair, spare parts, tools, maintenance materials, failure mode, and repair technology. The programs use legible pictures and photos to help workers to do their job well. Nowadays the programs are a part of vehicle maintenance.
280 POLISH ASSOCIATION FOR KNOWLEDGE MANAGEMENT Series: Studies & Proceedings No. 35, 2010 3. Conclusions CMMS programs give an opportunity to [1 16]: reduce the costs of maintenance, reduce stock level, increase productivity, increase financial liquidity, increase profits, and make the flow of information faster. The aims are achieved by better management of resources and organisation of labour. That is the reason why companies tend to apply CMMS systems. It should be mentioned that the systems can be universal or dedicated to particular applications. Moreover, the systems can be dedicated to large, medium or small companies. To sum up, CMMS systems are a part of modern management theory. Bibliography 1. http://www.well.com/user/vamead/demingdist.html 2. http://www.sur.pl/ 3. http://www.hci.com.au/hcisite2/articles/deming.htm 4. http://www.80 20presentationrule.com/whatisrule.html 5. http://www.gocfi.com/maximo.htm 6. http://www.transteka.pl/pl/produkty/aretics-cmms.html 7. http://www.e2000.com.pl/mp2_cechy_systemu.aspx 8. http://www.e2000.com.pl/infor_eam_cechy_systemu.aspx 9. http://www.e2000.com.pl/zmtv20.aspx 10. http://www.e2000.com.pl/szeor.aspx 11. www.neuron.com.pl 12. http://www.autodata.com.au 13. www.workshopdata.com 14. http://www.leader-service.pl 15. http://www2.moto-profil.pl 16. http://www.pcp.com.pl/pl/czytelnia/studia-przypadkow/110-tpm-jako-formaunowoczesnienia-dzialu-utrzymania-ruchu.html
Robert Kostek Computerised maintenance management systems 281 KOMPUTEROWE WSPOMAGANIE PROCESU EKSPLOATACJI Streszczenie Artykuł ten prezentuje programy przeznaczone do komputerowego wspomagania procesu eksploatacji (CMMS). Stosowanie tych programów ma na celu: zwi kszenie wydajno ci maszyn, racjonaln eksploatacje parku maszynowego, a w konsekwencji zwi kszenie rentowno ci przedsi biorstw. Programy te mog by przeznaczone dla okre lonych gał zi przemysłu, na przykład transportu samochodowego, lub mog by uniwersalne. Bez wzgl du na aspekt obszaru zastosowania zawieraj one podobne moduły takie jak: aktywa, magazyn, personel, plan zada, wiadomo ci i dokumenty. Programy te mog by traktowane jako poł czenie bazy danych i komunikatora, których stosowanie w praktyce przy piesza analiz danych, podejmowanie decyzji i wymian informacji pomi dzy pracownikami. Słowa kluczowe: komputerowe wspomaganie eksploatacji *This paper is a part of No WND-POIG.01.03.01-00-212/09 project. Robert Kostek University of Technology and Life Sciences Faculty of Mechanical Engineering