A Model for Automatic Preventive Maintenance Scheduling and Application Database Software

Transcription

1 Prceedings f the 2010 Internatinal Cnference n Industrial Engineering and Operatins Management Dhaka, Bangladesh, January 9 10, 2010 A Mdel fr Autmatic Preventive Maintenance Scheduling and Applicatin Database Sftware Abul Mukid Mhammad Mukaddes, Nazi Faisal Ahmed Chwdhury and Md. Min Uddin Department f Industrial and Prductin Engineering Shahjalal University f Science and Technlgy Sylhet, Bangladesh Abstract Maintenance is essential fr machines r equipments. Withut maintenance machine r equipment cannt wrk prperly thrughut its service life. T perfrm maintenance activities, the rganizatin needs t ensure maintenance scheduling in time. Case study shws that, in Bangladesh mst f the rganizatins are practicing preventive maintenance even sme are still practicing nly breakdwn maintenance. Amng them mst f the rganizatins perfrm the maintenance scheduling manually which is time cnsuming and which is als trublesme fr recrd keeping. In rder t vercme thse prblems, this research prpses a mdel fr preventive maintenance scheduling. Applicatin database sftware using C# and MySQL is develped supprting the prpsed mdel. This sftware may be treated as a helping tl t establish TPM partially in rganizatin by sharing infrmatin fr autnmus maintenance prgram and a scheduled/peridic maintenance prgram. Keywrds Preventive maintenance, Autmatic scheduling, Task sheet, Infrmatin sharing. 1. Intrductin Maintenance management plays a vital rle in manufacturing r even in service industries. Cmmercial rganizatins strive t make a reasnable prfit; public and nn-prfit rganizatins strive t perate in a csteffective manner. Either way, the businesses must deliver prducts r services at ptimum cst and n schedule in rder t be judged effectively [1]. T achieve these gals, rganizatins use enrmus mechanical, electrical, structural equipment, which need maintenance activity fr their prper functining. Almst every rganizatin has a maintenance department fr the maintenance f the equipments r machines. There are different ways used t manage the maintenance activities. An imprtant ne is preventive maintenance (PM) which is a schedule f planned maintenance actins aimed at the preventin f breakdwns and failures. It is the maintenance carried ut at predetermined intervals, r ther prescribed criteria, and intended t reduce likelihd f an item nt meeting an acceptable cnditin [2]. The primary gal f preventive maintenance is t prevent the failure f equipment and machine befre it actually ccurs. The ideal preventive maintenance prgram wuld prevent all equipment failure befre it ccurs. In mst rganizatin, this type f maintenance scheduling activity is paper based as well as manual. We als fund that the histries f maintenance are nt kept in an rganized way in mst f rganizatins. Sme f them keep the maintenance histry accrding t machine / equipment, sme accrding t date. Thugh sme rganizatins use ERP sftware fr maintenance scheduling, but they are still much mre expensive and cst ineffective fr mst f the industries f Bangladesh. Mrever, mst f the ERP sftware is client server based [3], which needs internet cnnectin but in Bangladesh still nw internet cnnectin with prper data transfer rate is nt available everywhere. In this paper we prpse a mdel fr preventive maintenance scheduling which can help t maintenance in an effective manner. We als develp applicatin database sftware, which can help t autmate peridic scheduling. The cmmercial sftware C# and MySQL [4] is used in creating the database. In rder t select the features prvided in the sftware, sme field data are cllected frm different rganizatins. The develped sftware fr preventive maintenance scheduling eliminates paper wrk and cst and makes the peridic scheduling mre accurate. It als includes maintenance histry, spare parts inventry cntrl and list f break dwn maintenance. Frm the maintenance histry, ne can analyze the previus data and can change the peridic schedule and take necessary steps. The prpsed mdel and database sftware will als decrease cst f replacement, system dwntime and better spares inventry management. It is shwn that the develped mdel and 167

2 database supprt sme gals and pillars f TPM (Ttal Prductive Maintenance) [5]. Thus it might help t implement TPM in an rganizatin. 2. Present Situatin f Maintenance Management A case study is perfrmed in several manufacturing and service industries in Bangladesh t cllect infrmatin f maintenance management. The case study srt ut the fllwing pints: There are three types f maintenance perfrmed. They are preventive maintenance, breakdwn maintenance and predictive maintenance. Preventive maintenance is cnsidered as mst imprtant amng three. Mst f the rganizatins have separate persns engaged fr scheduling the preventive maintenance. Mst f them have manual scheduling prcess. The maintenance histry is recrded manually. Mst maintenance activities are dne daily basis. The maintenance duratin f each distinct machine r equipment is selected accrding t manual f machine/equipment and sme times accrding t experience f experts. Operatrs are nt trained prperly in maintenance activities. Operatrs have little knwledge abut the basic maintenance activities like lubricatin, inspectin, tightening etc. There is little cperatin between the peratin and maintenance department. The peratr s philsphy is I perate, yu fix. Operatrs are nt respnsible fr cleaning and tidiness f the equipments area. The daily maintenance task sheet is prepared manually. 3. Prpsed Mdel fr PM Scheduling Frm the analysis f data cllected, we have fund that an autmatic maintenance scheduling can remve sme drawbacks f maintenance management exits in the industries f Bangladesh. T satisfy thse drawbacks, we prpsed a mdel fr preventive maintenance management as shwn in Figure 1. The relatin between the maintenance department and peratin department is als defined. In ur prpsed mdel, maintenance department is the centre f cntrl where a data base is kept. Maintenance department entries infrmatin t the database after a new machine r equipment is launched. The infrmatin might be cllected frm the fllwing three surces: manual f machines/equipments maintenance histry analysis experience f experts The database keeps the recrds f inserted infrmatin and accrding t the inserted infrmatin, the sftware autmatically prepare a maintenance schedule in daily basis. The input and utput (autmatic) f the database are shwn in Figure 3. The maintenance department culd retrieve the equipments which shuld be cnsidered fr maintenance fr a specific date. A task sheet f thse machines culd be printed. Accrding t the infrmatin in the task sheet, maintenance department wuld decide whether this task is dne by the department itself r send it t the peratins department fr the basic maintenance activities. Once the maintenance fr that day is finished, the feed back f the scheduled maintenance is updated in the database by the maintenance department. Database autmatically changes the maintenance schedule fr the fllwing days. If the maintenance department gets any breakdwn infrmatin frm the plant, they make the breakdwn maintenance immediately and revise the maintenance schedule in the database fr that specific machine/equipment. The maintenance histry f a specific machine r equipment is als maintained in the database. Thus by srting majr breakdwns and reccurring breakdwns frm the maintenance histry, the maintenance department can take crrective actins. Beside these activities, maintenance department als perfrms time based maintenance activity. The peratin department mainly perates the plant; beside it in ur prpsed mdel peratin department perfrms basic maintenance activities which are given in the task sheet. The maintenance department wuld train the peple f peratin department fr these basic maintenance activities. Our prpsed interactin f the maintenance department with the database is shwn in Figure 3. We als prpse the fllwing activities f the maintenance department and peratin department- Maintenance department Repairs & Engineering 168

3 Preventive maintenance Planning and scheduling and rescheduling Stres cntrl Perfrm time based maintenance Training (the peple f peratin dept.) Recrd keeping and Data base management Reprts and analysis Budgeting & financial planning Quality Assurance & Safety Operatin department Keep the peratin smth Perfrm Basic Maintenance Activities such as: Cleaning, Lubricatin, Adjust, Inspectin Receive and deliver wrk rder t maintenance department. Get training frm maintenance department. T achieve better safety, health and envirnment wrk with EHS department Reprt abnrmalities t the maintenance department. 4. Applicatin Database Sftware In rder t implement the prpsed maintenance mdel, a huge class f sftware is needed fr varius develping stages. Much cmmercial sftware is available which shuld be purchased t implement the system. Of curse sme sftware shuld be develped t prvide desired feature t the maintenance department. An imprtant task is t create database sftware. A large class f database is a significant criterin fr such a mdel. One thing shuld be kept in mind during the develpment f sftware is that sftware shuld be flexible t use and be simple t suit the existing infrastructure in rganizatin [6]. The steps given in Figure 4 are fllwed t create a database supprting the prpsed mdel described in the preceding sectin where the input and utput f the data base are shwn in Figure

4 Figure 1: Prpsed maintenance scheduling mdel 170

5 Figure 2: Maintenance manager and scheduling Figure 3: Input and utput f the database Figure 4: Steps f develping sftware The features prvided in the database, are selected frm the infrmatin cllected frm different industries with the help f sme questinnaires. With its intuitive and user-friendly design the develped database integrates preventive maintenance wrk rder, scheduled wrk rders, spare parts inventry cntrl, maintenance histry and equipment searching t benefit the maintenance manager. Database schema is created using clumns and rws in tables. We use MySQL database sftware [5]. Cmputer cde was written in C# language using visual studi 2008[6]. The first windw f ur created database is shwn in Figure 5. Sme pictrial view f the features f the develped applicatin database sftware is given belw. It includes new data entry (Figure 6), autmatic scheduling fr a specific date, specificatin f an item, a task sheet that will be given t the maintenance peple fr prper actin. It als prvides the searching ptins f any equipment r spare parts. The database maintains the histry f previus maintenance (Figure 7) and spare parts inventry (Figure 8). Huge number data culd be kept in the develped database. The database manager shuld update the data base after the maintenance wrk every day. It will autmatically reschedule fr the fllwing days. 171

6 Figure 5: First windw f the applicatin database sftware Figure 6: New data entry 172

7 Figure 7: Searching Figure 8: Spare parts inventry 5. Relatin with TPM The prpsed mdel and data base sftware agrees with sme bjectives and gals f TPM. Thse are summarized in Tables 1 and Cnclusin A case study n the present situatin f maintenance management in several industries in Bangladesh is perfrmed. Based n the infrmatin frm the case study, a mdel fr preventive maintenance scheduling is prpsed as well as database sftware is develped supprting the mdel. In the develped sftware we tried t autmate preventive maintenance the scheduling. The develped sftware will generate the infrmatin f previus maintenance histry 173

8 that helps in decisin making f predictive maintenance. We tried t intrduce an easy and cnvenient mdel f maintenance scheduling with the help f a simple but effective maintenance scheduling sftware. S the utcme f this research will benefit first and fremst the maintenance manager f industries in Asian develping cuntries like Bangladesh. Table 1: Relatins with TPM gals S/L TPM gals [5] Relatin with prpsed mdel 1. Eliminatin f the six big lsses (dwn time, speed, and defect) Thugh the develped sftware has nt the facilities fr recrding the six big lsses but it is recmmended t further develp the sftware t make it pssible t recrd and calculatin f these lsses and verall equipment effectiveness by it. 2. An autnmus maintenance Interactin f the maintenance department with peratins prgram department 3. A scheduled maintenance prgram Autmatic scheduling f preventive maintenance fr the maintenance department 4. Increased skills f peratins and The maintenance department will train the wrker f peratins maintenance persnnel 5. An initial equipment management prgram department in regular basis It is indirectly facilitated by the spare parts inventry part f the develped applicatin database sftware. Table 2: Relatin with TPM pillars S/L TPM pillars [7] [8] Relatin with prpsed mdel 1. Planned Maintenance Prper maintenance scheduling 2. Training & Educatin Training & Educatin f persnnel is necessary fr ur prpsed mdel. We strngly recmmended it. 3. Fcused Imprvement T implement the mdel, Crrelatin amng several departments shuld be strng enugh, which is essential fr cntinuus imprvement. 4. Quality Maintenance Analysis frm the maintenance histry helps in quality maintenance. 5. 5s (Srt, Systematic, Shine the wrkplace, Standardizatin, Self discipline) The prpsed scheduling mdel is nt directly invlved in implementing 5s, but thrugh tidiness, cleaning and srting are facilitated by autnmus maintenance f peratin department and the spare parts database f ur sftware. 6. Office TPM Develped database sftware reduces paper wrks thus ffice TPM is als 7. Safety Health & Envirnment 8. JISHU HOZEN = Autnmus Maintenance facilitated. Trained peratrs Basic maintenance activities f the peratin department and crrelatin with maintenance department References [1] E. Hartmann, D. J. Knapp, J.J. Jhnstne and K.G. Wrd, Hw t Manage Maintenance, American Management Assciatin [2] A. Kelly, 1991 Maintenance Planning & Cntrl, Affiliated East West Press Ltd. [3] D. L Waller, 2003 Operatins Management A supply chain apprach, Internatinal Thmsn Business Press. [4] L. Welling, L. Thmsn, PHP and MySQL Develpment, Sams Publishing. [5] S. Nakajima, 1984 Intrductin t TPM, Japan Institute fr Plant Maintenance. [6] K. Watsn, Eric White, 2006 Beginning Visual C# 2005, Wiley Publishing, Inc. [7] M. A. A. Hasin, 2007, Quality Cntrl and Management, Bangladesh Business Slutin. [8] A.K.M. Masud, A.-A. Khaled, S. Jannat, A.K.M. S. A. Khan and K. J. Islam, 2007, Ttal Prductive Maintenance in RMG sectr, A case: Burlingtns limited, Bangladesh, Jurnal f Mechanical Engineering, ME