Draft Copy. By Raymond Grosch Senior System Analyst IntelliSys Inc. IntelliSys Inc. White Paper

Transcription

1 IntelliSys Inc. White Paper Draft Copy 09 W. Washington Chicago, IL By Raymond Grosch Senior System Analyst IntelliSys Inc.

2 Contents Introduction 2 Problem Statement 2 Previous Options MaintenanceVIEW Solution Benefits Implementation 4 Summary 6 Introduction In the Digital Age, the ability to manage a broad range of asset information has become a prerequisite to a successful maintenance management system. To meet the demands of greater efficiency and lower operating costs integrated solutions for facility maintenance management are required. This new approach to maintenance incorporates real-time interface for status monitoring, predictive maintenance reporting and historic data collection for forensic analysis of mechanical assets. An integrated system can collect, manage, organize and provide strategic asset information to all levels of the enterprise. Problem Statement Today most facilities operate with disparate information management solutions. Maintenance personnel use a combination of paper records and multiple computerized records to keep track of asset maintenance and condition. Finding needed asset information and documents is often difficult and time consuming. Maintenance information is often limited to the maintenance department. Asset information can also be strategic resource for management and engineering levels on the enterprise. Breakdown maintenance or fixing assets as they fail, and corrective maintenance, redesigning assets that experience repetitive failures is often the norm with many facilities. Predictive procedures help to reduce costs by identifying maintenance issues before failures occur and eliminating the need for emergency repairs. Calendar based scheduling for inspection and lubrication usually results in excessive over scheduling maintenance task wasting time and money. 2

3 Previous Options Previous Options Building an integrated maintenance system has always been an idea goal. However project costs associated with expensive consultants and programmers have prohibited progress. MaintenanceVIEW Solution Benefits MaintenanceVIEW software provides a unique integrated suite of facility management applications designed to work together, eliminating the struggle to maintain compatibility between disparate software products. Some of the benefits of the integrated approach provided with MaintenanceVIEW software include: MaintenenaceVIEW Solution Benefits Benefits 1. MaintenanceVIEW provides a platform for development of a facility strategic information system. It is easily integrated with optional real-time data updates and surveillance to produce predictive maintenance reports. 2. All data can be stored in a common network accessible open database such that management and engineering can also easily access strategic data.. The application provides a low cost, easy to use rapid development tool set designed to integrate maintenance management, asset records and manufacturer data. Asset record such training video and video inspection reports have also been incorporated. 4. Automated surveillance data such as runtime hours can be updated in the system. Many maintenance tasks can then be scheduled based on actual use rather than on calendar time improving efficacy by reducing work orders and associated time consuming administrative work.

4 Implementation 4 Implementation The MaintenanceVIEW application has evolved over the past twenty years. The program maintains its original architecture while the database engine has been update to Microsoft SQL and many user customizable features have been added. The following examples provide different strategies in implementing the program. Example 1 Garrett County Maryland The Garrett County Utility staff maintains a number of small community water production, treatment and distribution systems. Several wastewater collection and treatment systems are also supervised by the department. Information is organized by system, process area and device. Tasks are scheduled by both calendar time and use information. Utility staff are dispatched weekly with a work order list for maintenance duties as well as a materials requirement list. The program user interface is configured with a map of the County as part of the main menu. Buttons are provided for each location to allow easy access to the local system overview site asset records. Asset records incorporate photographs of the equipment as well as current elapsed time meter readings for specific equipment. MaintenanceVIEW provides for both fixed asset and rotating equipment. Water reservoirs and manholes as well as pumping and process equipment can be maintained with the system. Preventative maintenance scheduling and predictive maintenance reports are available in the application. Manufacturer and vendor records can easily be kept with this application. Work order management and perpetual inventory modules are also a standard component of the software application. The SQL asset data base can also allow access to other software application such as GIS, when the database user rights are configured for this option. 4

5 Example 2 Plover Wastewater Utility The Plover wastewater treatment facility was constructed in 1986, and upgraded in 1998 to provide biological phosphorous removal, and in 1999 to construct auto-thermal aerobic digesters, and revise the preliminary treatment building. The upgrade was completed in January The facility is designed to clean 1.8 million gallons of wastewater per day, and remove 5,00 pounds of BOD (Biochemical Oxygen Demand) per day, 6,997 pounds of suspended solids per day, and 99 pounds of phosphorus per day. Rich Boden the plant superintendent was an early implementer of computerized maintenance program. Soon after the plant was put into operation Rich sought out a CMM (Computerized Maintenance Management) and selected MaintenanceVIEW. When the plant was updated with SCADA in 1998 Rich linked the maintenance system to new SCADA so that runtime hours would be updated in the maintenance system automatically every day. Rich also added predictive maintenance reporting capability to the system. Rich recently commented that the predictive maintenance feature saved several thousand when a quick report verified the remaining lift station pumping capacity. The original program installed at Plover use a MS Access data base. The MaintenanceVIEW program is provided with a powerful report writer. However Rich was familiar with the Access data base tools and he chose to use the Access tools to create some of his reports. Another feature of the program implemented at Plover is the inventory and purchasing module. The perpetual inventory system automatically adjusts inventory items as parts are used on work orders. 5

6 Example Moorhead Wastewater Utility The City of Moorhead Wastewater Department was anther early implementer of computerized maintenance management. An early version of MaintenanceVIEW was installed over two decades ago. The application has one through two major revisions in the past decades but the equipment history and services records are well documented in the current system. Moorhead wastewater manages over 650 asset items with their maintenance system. Over 900 preventative maintenance tasks are assigned in the system. To minimize administrative work the system imports runtime data from a SCADA system so that work orders can be scheduled based on actual equipment runtime rather than calendar time. With approximately 100 preventative Maintenance work orders week the wastewater facility employs an administrative assistant to generator, print, distribute and close work orders. Many standard reports are available including Cost Center, Craft and Labor, Department, Employee, Manufacture, and Vendor Reports. The administrator prints standard reports monthly for management and can easily create custom reports, such as a cost of maintenance in a specific process area, on an as needed basis. Because the report formats are in an ExcelTM format it is easy to resort data using the spreadsheet controls. Summary 6 6 SUMMARY MaintenanceVIEW is a proven solution for automating maintenance management in the Utility Industry. The current version provides preventative and predictive maintenance modules designed to help reducing operating and administrative costs. The open data base format is designed to integrated with other facility management solutions.