Computerized Maintenance Management Information System for Process Industries: A Critical Review

Transcription

1 Discovery REVIEWS The International journal ISSN EISSN Discovery Publication. All Rights Reserved Computerized Maintenance Management Information System for Process Industries: A Critical Review Publication History Received: 22 April 2016 Accepted: 20 May 2016 Published: 1 June 2016 Citation Pawan Kumar Verma, Tewari PC. Computerized Maintenance Management Information System for Process Industries: A Critical Review. Discovery, 2016, 52(246), Page 1196

2 Computerized Maintenance Management Information System for Process Industries: A Critical Review Pawan Kumar Verma 1, Dr. P.C. Tewari 2 1 M.Tech.Scholar, Department of Mechanical Engineering, N.I.T. Kurukshetra, Haryana, 1 er.pawan23@gmail.com: 2 Professor, Department of Mechanical Engineering, N.I.T. Kurukshetra, Haryana, 2 pctewari1@rediffmail.com Abstract Computerized Maintenance Management Information System offers the highest availability of production equipments and results in the effective planning, controlling and scheduling the maintenance activities. It provides the managers and engineers, timely information for sound decision making for maintenance work. The application results in reduction in response time, better accuracy of information, management of work orders, reduction in paper work, minimization of information leakage, increased safety and risk management and centralization of units of a maintenance department. The analysis of the past records of each unit ensures the optimum frequency of maintenance programs and development of maintenance schedules. CMMIS software are increasingly being used in Process Industries in reduction of overall annual maintenance cost, detailed work order for each maintenance job, day to day maintenance schedule and reduction in the total downtime of machines and other plant facilities. Keywords: Maintenance Planning and Control, Computerized Maintenance Management Information System (CMMIS). 1. INTRODUCTION 1.1 MAINTENANCE It is a combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it can perform the required function. With technological developments the responsibility of the maintenance engineers has increased considerably due to over growing complexity and size of industrial organizations. The maintenance actions can be either preventive which are carried out at predetermined intervals or corrective which are carried out after a fault is recognised. 1.2 COMPUTERIZED MAINTENANCE MANAGEMENT INFORMATION SYSTEM Computerized Maintenance Management Information System (CMMIS) is simply application of computers for quickly and efficiently deciding, planning and organizing various jobs for effective plant maintenance. There are many factors to consider in determining whether a CMMIS can benefit your operation. The most important factors relate to reduced cost, better organizational methods, reduced paperwork, and improved communications. From a cost standpoint, if planned maintenance work is less than 90% of the total maintenance work load, Page 1197

3 if craft productivity is less than 80% of capacity, or if craft overtime is more than 10%, a CMMIS can be very helpful. If the maintenance inventory cost, including holding cost, is more than 30% of the annual maintenance budget, a CMMIS is efficient to be used. 2. LITERATURE REVIEW Jones and Collis [1996] examined the use of Computers in Maintenance Management and identified the various maintenance activities that have been computerized. He reviewed the level of use of computers across the building management industry and assessed the level of user satisfaction with Computerized Maintenance Management System. The tools used were Computers, whose primary area of work was building repairs and maintenance that benefit from the application of the principles of Re-engineering. Medlin et al. [1999] discussed two types of CMMS. One was Database/Calibrator Systems and the other, Database/Calibrator/On line Systems. Both systems utilized a computer database of field devices in conjunction with smart calibrators. Access to calibration and test history information is readily available to any auditor. The databases offered a level of security that makes tampering with this information practically impossible. The systems presented the information and calculations in a consistent format. Singh et al. [2000] dealt with the implementation of Condition Based Maintenance (CBM) at Panipat Co-Operative Sugar Mill, Panipat, new trends and latest developments in the field of Maintenance Engineering that is CBM, CAMP, Terotechnology etc. and concluded that CBM along with CAMP, when applied together, could prove a very powerful tool in process of total automation, where every control is to be mechanized and overall integration can be performed with the help of computers. Fostiak et al. [2001] explained that the developments in computer software technology made it possible to economically integrate relevant plant operations, equipment, planning, and systems information. That feature permitted easy access by all appropriate personnel within the corporation. When those new technologies were blended with new management processes relating to maintenance, outages, asset condition assessment, project justification and prioritization, unit dispatch, and reservoir management, the results were improved efficiency and reduced costs with high reliability. Sloane et al. [2003] discussed an ongoing medical informatics and business process reengineering research project. The Joint Medical Asset Repository (JMAR) was a relational database system created to integrate very diverse medical supply and medical maintenance management information from the US military services existing heterogeneous database systems. The emerging consensus seemed to be that the JMAR Meta database became an invaluable and efficient tool for managing the heterogeneous information systems and databases. Acevedo et al. [2005] designed and implemented a Computerized Maintenance Management System (CMMS) to be used at the Chilean Naval Hospital Biomedical Engineering Department. It was designed to meet the specific needs of this military facility and followed Page 1198

4 the Generic Clinical Engineering Maintenance Management System suggested by Association for the Advancement of Medical Instrumentation. Carnero et al. [2006] analyzed the problem of the selection of the CMMS software most effective for a company. A high percentage of CMMSs were poorly used or eliminated without providing benefits. For the elaboration of the evaluation system the methods maximum Eigen value, geometric averages and programming by goals had been applied. The utilization of different methods for the capture of decisions in the CMMS s selection allowed the decision maker to see the differences in the classification of alternatives and showed the reliability of the system of evaluation designed. The system developed had been tested in a hospital. Ashayeri et al. [2009] discussed that the Computer Aided Maintenance Resource Planning was a major challenge because the maintenance operation s environment was usually traditional and unfavourable to change. The Computer Aided Planning system for a maintenance business unit served a number of manufacturing facilities, each consisting of the Corrective Maintenance activities of all CNC machines within the different manufacturing sites which helped in conducting different maintenance activities of manufacturing units in a more synchronized way, finishing well in time and lead to lower costs. Halawani and Burhanuddinv [2010] developed a cost analysis showing a continuing challenge to maintenance management in all types of organization. In this paper, a model relating the cost of maintenance action in failure-based problem is presented. The main advantage of the proposed cost model is the flexibility and expandability obtained from using the same expression for several maintenance actions. Then, Decision Making Grid model is used to implement maintenance strategies. The results presented showed that cost model could have been used in failure-based maintenance systems, as it provided a powerful tool for taking into account the interaction between the frequency of failures and downtime. Using this re-positioning into Decision Making Grid model, managers were able to select maintenance policies more economically. Gomez and Carnero [2011] developed a model to select the most satisfactory CMMS in a hospital. The model consisted of two differentiated stages: the selection of finalist companies and the selection of the most suitable CMMS. The multicriteria technique ELECTRE II was used in both stages. The fact that the selection of the CMMS was carried out in a public health service had a decisive influence on the CMMS eventually purchased, since the restrictions and the standardization to which the organizations dependent on regional public administrations were subject steering the purchasing decision towards an alternative that was not even considered in the analysis of the previous alternatives. Kumar et al. [2012] discussed the development of computerized maintenance management information system for a fertilizer plant. Which was versatile, less complicated, less costly and less time consuming computer software. CMMIS software aimed to an informational tool for maintenance activities and also reduced total downtime, overall annual maintenance cost, frequency of failure of the machines. Page 1199

5 Ramachandra et al. [2013] implemented a computerized maintenance management information system (CMMIS) according to the requirements of a medium scale industry. The intention was to assist the maintenance and other activities of the industry in an organized manner to assist management in controlling department like marketing, production, stores and purchase which are inter-linked for the better functioning of the organization. Further, it is stressed at this stage that, there is an utmost need to train the employees, instigate them to take up challenging jobs and to get involved totally for the success of the industry. Beni [2014] studied and established a management system for maintaining knowledge in the Iranian ministry of petroleum. The main functions of the system included units and equipments reliability analysis, failure mode analysis and maintenance benefit cost analysis. For an oil and gas industry, the safety, and environment effects caused by equipment malfunction is more essential than the other industries. The paper presented the current status and the benefits of implementing the CMMS in Iranian gas industry. The major components of this plan were identified and a pilot system was implemented in some sector of Iranian Ministry of Petroleum. Henry et al. [2014] studied the Upgraded Pillar Point Sewage Treatment Works (PPSTW), Recursive Auto-Regression (RAR) modelling technique newly adopted by The Drainage Services Department (DSD) of Hong Kong China, which automatically predict specific equipment s Remaining Useful Life (RUL) and compared the lead time of components delivery and process time of overhaul sub-contracting so as to establish an optimum preventive maintenance schedule with delivery, resources and cost optimization. Prediction accuracy of the developed RAR model was verified by numerical simulation with inputs to CMMS condition monitoring engine. Marks et al. [2015] reviewed landside airport information management systems, and their connections and interoperability with other systems and with the key airport users. A CMMS enabled an airport to provide the degree of comfort and convenience expected by its customers. The CMMS facilitated greater efficiency in operating procedures, improved inventory management, and reduced costs associated with maintenance labour and operations. The Relational Database Management System (RDBMS) database stored information and the data deemed relevant to airport operations like object tables for storing information on equipment, tools, facilities, vehicles, employees, schedules, utilities, systems, schedules, maintenance plans, schematics, inventories, customers, vendors, assets, and work orders. Dahiya et al. [2015] dealt with a critical literature review of the research work regarding Computerized Maintenance Management System (CMMS). The management of a large quantity of data was taken as an important aspect for the improvement of operation and safety, cost reduction, increase of availability and increase of lifespan of the machines and system. All these were to be efficiently managed by the use of a CMMS software. Page 1200

6 3. CONCLUSIONS The paper deals with the critical review of the research work done related to Computer Maintenance Management Information System for different types of manufacturing and service sectors. The following aspects conclude the application of CMMIS: 1. It emphasizes and enhances the processes related to maintenance, asset condition assessment, project justification and prioritization, unit dispatch, and inventory management. 2. The result gives improved efficiency, reduced costs with high reliability and conducts different maintenance activities of manufacturing units in a more synchronized and automated manner. 3. CMMIS contains a feature for accumulation of historical data about maintenance and makes tampering with this practically impossible so it is an invaluable and efficient tool for managing the heterogeneous information systems and database. 4. There is a reduction in total downtime, overall annual maintenance cost, frequency of failures of the machines. Consequently, the maintenance engineer is able to get dayto-day maintenance schedule, to predict maintenance budget and maintenance policy using CMMIS. 5. The practice of CMMIS gives an effective maintenance management of manufacturing facilities throughout their life cycle with increased plant efficiency. 4. REFERENCES 1) Acevedo F.J., Fuentes J.E. and Enderle J.D. (2005). Design of Computerized Maintenance Management System for the Chilean Naval Hospital Biomedical Engineering Department. 27th Annual International Conference of the Engineering in Medicine and Biology Society, pp ) Ashayari J. and Teelan A. (1996). A Production & Maintenance Model for the Process Industry. International Journal of Prod. Res., Volume: 34, No: 12, pp ) Beni S. S. (2014). Implementation of Computerized Maintenance Management System in National Iranian Gas Company and sub-companies. Proceedings of the 2014 International Conference on Industrial Engineering and Operations Management, January ) Carnero M. C. (2006). An evaluation system of the setting up of predictive maintenance programmes. Original Research Article Reliability Engineering & System Safety, Volume: 91, Issue: 8, pp ) Dahiya R., Tewari P. C. (2015). Computerized Maintenance Management System: A Critical Literature Review. International Journal of Applied Engineering Research, ISSN Vol. 10 No.35. 6) Fostiak R. (2001). Computer Maintenance Management Systems (CMMS) for hydroelectric power systems. Power Engineering Society Winter Meeting, IEEE Volume: 2, pp ) Gabbar H. A. (2003). Computer-aided RCM-based plant maintenance management system. Original Research Article Robotics and Computer-Integrated Manufacturing, Volume: 19, Issue: 5, pp Page 1201

7 8) Gomez A. and Carnero M. C. (2011). Selection of a Computerized Maintenance Management System: a case study in a regional health service. Journal: Production Planning & Control, Volume: 22, Issue: 4, pp ) Halawani S. M. and Burhanuddin M. A. (2010). Machine Repositioning for DMG Analysis Based on the Maintenance Cost. Second International Conference on Computational Intelligence, Modelling and Simulation, pp ) Jones K. and Collis S. (1996). Computerized Maintenance Management System. Processing of UK Seminar, pp ) Marks A. (2015). Airport Information Systems Landside Management Information Systems. Intelligent Information Management, 2015, 7, ) Medlin J. (1999). Computerized Maintenance Systems -An Overview of Two Basic Types for Field Devices. Industry Technical Conference Record of 1999 Annual Publication, pp ) Ramachandra C. G. and Srinivas T. R. (2013). Design, Development and Implementation of Computerized Maintenance Management Information System (CMMIS) for a Selected Medium Scale Industry, International Journal of Science, Engineering and Technology Research (IJSETR), Volume 2, Issue 8, August ) Saharkhiz E., Bagherpour M., Feylizadeh M., Afsari A. (2012). Software Performance Evaluation of a Computerized Maintenance Management System. Eksploatacjai Niezawodnosc - Mainten ance and Reliability vol.14, issue 1. 15) Singh R. (2000). Behavior Analysis & Maintenance planning of Sugar Industry. Dissertation report, Kurukshetra University, Kurukshetra (India). 16) Sloane E. B., Rosow E. and Adam J. (2003). Integration of heterogeneous medical supplies and computerized medical maintenance management (CMMS) databases and decision support systems. Proceedings of the 25th Annual International Conference of the IEEE Volume: 4, pp Page 1202