XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUÇÃO. IMPLEMENTED INFORMATION TECHNOLOGY IN THE MAINTENANCE SECTOR Aurélio Zoelner Dallarosa (UTFPR) aurelio_zoelner@yahoo.com.br Aldo Braghini Junior (UTFPR) aldo@utfpr.edu.br Luciano Scandelari (UTFPR) scandelari@utfpr.edu.br Marco Antonio Subtil Macedo (UTFPR) masmacedo@terra.com.br The implementation of a software for the maintenance management, in a Chemical company, in the city of Ponta Grossa - Paraná - Brazil, aimed to improve the Industrial Maintenance Sector, throughout the register integration of predictive annd preventive maintenance from all the factory s equipment, as well as the Bills of Service, integrated by this system. In seasoned companies, the biggest issue is keeping the equipment, with many years of usage, without flaws; on the other hand, the history of the equipment gives an aid to the manager when it comes down to making a decision. In the new companies, the biggest problem is to ensure the machineries function the same way as the seasoned companies do, but, with a twist, the new companies do not posses history, only the manufacturer s manuals, transferring to the manager the responsibility of making the right choice, avoiding the failure. This responsibility becomes extremely subjective to the person and not to the maintenance management. The main goal of this software is to help the manager in the decision making, aiming at a longer and bigger life endurance for the equipment, offering a lower cost to the organizations of the company and also to control the performance of requester and manager, becoming the study presented here. Palavras-chaves: Software, Maintenance, Preventive, Predictive.
1. INTRODUCTION A Chemical company, located in the city of Ponta Grossa PR, observed the necessity to develop a maintenance software, seeing that the maintenance has the obligation to keep the equipment supervised by it, trustworthy and safe for its users and operators, respecting people and environment as a whole. As said by Souza Jr. (2004) with the software s help, the maintenance manager receives the complete information, observing how its sector is and, acts not accordingly his/her habits and behavior tendencies but, verifying problems, flaws and tendencies in some specific cases and of bigger relevance to the organization. Thus, the maintenance manager can verify and conduct his team to a dominant and comfort situation when facing other sectors from the company, specially the production, for this is the biggest direct client of maintenance, to fulfil its goals and answer the external clients, between deadlines and specified qualities. For this reason, the failure indicators, mechanic failures or even flaws that are pinpointed by the system, could be extremely useful for all the organization or company, for, with it, the manager can act ahead of the basic simple or complicated equipment defect, not putting on disposition its function to the system. For Campos (2006, p. 13) a system is a processor formed by elements which interact, whose input is information and/or energy and/or matter and which output is information and/or energy to fulfil objectives. The Bills of Services are usually requested to the maintenance manager by an electronic system, which means, any user can make a request register of Service or improvement at the sectors who they work by the BS (Bill of Services). These orders are registered in the system and the manager grants the access through the users login, in order to obtain a better security and tracking of requests. These orders follow a sequential number code, having a filter, per requester, area of work, area or sector in which the equipment is located. With the Bills of Service opened by the requester, the manager qualifies into categories to indicate the priorities, and also, to verify the amount of working force, team s movement, control and programming of reposition parts regarding the warehouse. Beyond the advantages mentioned that the software promotes to the maintenance manager and the improving of quality in the production as a whole, another goal for this implementation is to build a control list of the equipment and of the failures pinpointed by it, remembering that in a recently built company, there is not such a register, making difficult the immediate problem solution, sometimes very easy to be sorted out. 2. SOFTWARE FOR MAINTENANCE The research was conducted in a multinational chemistry company, which was recently built in the city. This company began its activities in November 2005, processing 2
Calcium carbonate, whose raw material is used in this company unit, coming by ship from another unit, located in Turkey. The carbonate is applied in the process of fabricating paper, as a mineral charge or as a cover finishing print, giving more quality in the paper finishing, the bigger the carbonate charge is. As an example we can mention the magazine paper. In Ponta Grossa, the carbonate is prepared and delivered to companies in the paper business, located in various states from Brazil: Paraná, São Paulo, Santa Catarina, Rio Grande do Sul among others. In order to achieve a customer assistance excellence, all companies search for various solutions that provide quality and trust for the products generated by them. They seek the costumer s complete satisfaction. A management system is a compilation of inner related elements, used to establish the policy and the objectives and to fulfil these objectives. (ABNT, ISO 14001, 2004, p. 2) Some companies, that are in the market for quite a while, go through the following problems: their facilities are too old, their equipments are obsolete and are in need of frequent technical inspections. On the other hand, when the companies are new, the problem is that they do not posses equipment history and the only thing left for the manager are the manuals. Many times there are performance comparisons from a similar equipment, however, this practice can lead into mistakes, regarding the equipments do not react the same way in all productions, in all factories, nor present exactly the same failures. As this company fits on the second case, it was internally developed a system to manage and built a historic from all equipment from the areas of: Mechanics; Electrics; Instrumentation. For the electrics and mechanics the maintenance are being programmed as follows: Preventive maintenance; Predictive maintenance; Purification. For the instrumentation there are some differences, due to calibration and instrument verification, but also following the programming logic as in the other areas: Checking; Calibration. The software is called Gman (Maintenance manager) and, this program generates all the information in weekly and monthly reports format for all the areas. In the database is possible to verify all the interventions on the equipments, which are separated according to: Area; Equipment; Local; 3
TAG; Brand; Sector. In the picture below it is possible to verify the system s structure, in which is possible navigate to all sector departments, collect and/or alter information and equipment data in general. Also, in this main screen, the manager as well as the users, can use to implement data for the factory maintenance management department: Picture 1 Gman main screen According to Kardec, (2002), verifying the types of failure, flaws or equipment disabling for the process, it is also possible to obtain a history of each equipment, containing the maintenance information conducted on it or the spare parts of each equipment.. This equipment information are stored in the system database. The company basically works with preventive and predictive maintenances in the equipments from the process. On the next topic, the work instructions, the types of maintenance in the sectors of mechanic, electric and instrumentation will be approached. The civil maintenance civil is executed by an outsourced company. 4
3. SOFTWARE S MAINTENANCE MANAGEMENT Being the company a multinational and using imported technology, there is a certain difficulty in the system s deployment leading the maintenance team to have doubled attention, avoiding nationalizing some equipments the wrong way. Plus the equipment is new and do not posses a regular history. Thus, it is of great importance the monitoring, so that the equipment have a longer duration and the sector shows security and reliability to the production department. This research will approach, as an example, only the mechanical maintenance department, although, the system extends itself to other maintenance areas. Work instructions regarding the mechanical maintenance operational procedures, in Ponta Grossa, will be established. 3.1. Definitions and Abbreviations - Gman Maintenance manager - Corrective maintenance Takes place when the equipment breaks or there is a flaw. - Preventive Maintenance It is stipulated a deadline to execute the maintenance in every equipment, given its history and work place. - Predictive Maintenance It is a type of maintenance, which evaluates the conditions from the equipment, helping the preventive maintenance and upgrading the final cost. - BS Bill of Service; - Crusher Bricking area; - Dry System Tube s mill; - SMD Base product tank; - PX1 e PX2 Aspheric mills, moist grind; - Other System Air compressor, water pump e chemicals in general; - Load out Shipment area of the final product. 3.2. Responsability and Authority Mechanic Keep the equipment running properly for the users, maintaining the equipment running as requested via Bill of Service (BS), or accordingly maintenance programming. Technical Mechanic Provides technical support to the mechanic maintenance, doing technical sketches, technical planning, and the programming of the maintenance from the equipment close to the production. 5
3.3. Activities Descriptions 3.3.1. Preventive maintenance In the beginning of every month a list will be printed with the equipments which inspections will reach their deadlines on that period of time. On the deadline period from the preventive inspections, intervention and vibration analysis reports will be analyzed, to evaluate the evolution from the rolling state. After this procedure the equipment will have its intervention, if necessary. If the inspection is not necessary, the planning reschedules the date from the preventive maintenance and follows the equipment through predictive maintenance, until the rolling ca not be used any longer. Being necessary the inspection, a convenient date must be scheduled with the supervision area. In the equipment inspection these are the procedures: turn off the engine, request the removal of the fuse by the control file, unplug and take the equipment for inspection. In case of centrifugal pumps, route for a outsourced company for the maintenance. In the inspection the rolling conditions, rotor balance conditions, axis curve, braces, gasket etc. will be evaluated. After the inspection, install equipment, plug, execute lining (if necessary), request the placing of the fuse, freeing the control file. Conduct test on the equipment and measurement of functioning conditions after installation (noise, vibration, engine chain). When approved, the equipment will be allowed to function. Obs.: The reserve equipment remain without deadline for the next inspection and will only be verified at the moment of use, by the maintenance system. 3.3.2. Predictive maintenance Every month, the outsourced company, conduct the analysis of the equipment vibration which affects the production and the quality of the process. After this analysis, the company sends a report with the conditions of every equipment. This report has the objective to inform the conditions of the monitored equipments during the month, showing diagnosis and necessary recommendations, as well as the changes found when previous measurements are compared. In the vibration analysis measurements of velocity, acceleration and acceleration package, collected by the velocity meter by the equipment bearing are taken. The collected data are stored in a database of the company responsible for the measures and they will be at the company s disposal. For the analysis result evaluation, the gathered values are divided into 03 (three) classes, according to the vibrating levels found: - Normal: Normal levels of vibration. - Alarm 1: Values reaching alerting levels. No being necessary immediate intervention, but requiring attention, for there is already a flaw. - Alarm 2: elevated values of vibration, special attention being necessary and intervention as quickly as possible to avoid equipment failure. In the analysis report, there are tendency 6
graphics for the equipment in Alarm 2.Analysing the graphics, the equipment that needs a higher priority of maintenance is chosen. Thus programming with the area supervision the equipment stoppage for the maintenance. To ease the management following the number of equipments in Normal, Alarm 1 and Alarm 2 are presented in graphics by alarm type and by frequency of flaws, and the diagnosis and recommendations for the fixing of the equipment in alarm situation are synthesized in spreadsheets. 3.3.3. Users assistance Frequently, when a factory sector, even when it is the maintenance sector, needs a procedure of any kind done (corrective, preventive or predictive maintenance), it must request it by a Bill of Service BS, previously filled in at Gman. The executant area will do the execution data programming, as a priority, the available manpower and the availability to stop the machinery or equipment. After the fulfilment of the service the executant(s) functionary(ies) fill in the date or the dates (in case that the service lasts more than one day) when the services were fulfilled, with the beginning time, ending time and the functionary(ies) registration(s). The functionary must describe the service done to keep the equipment history. After the service s conclusion, the executing functionary, or just one of the executants registers the hours and the closure of the BS at Gman, with the concluding and service time. 3.3.4. Registers - Equipment history - Preventive maintenance plan - Concluded Bill of Service - Bill of Service (pendent) - Vibration analysis report Through this structure the software is fed by the database so the system has enough information for the manager and his/her team to develop all the activity within normality and organizational programming. After four years of operations, the factory unit presents a very satisfactory control system, avoiding failures or equipment flaws. This software is being used in a simple and regional way, regarded the database Access 2003 is kept in a own company service and this generates reports and other information to the maintenance manager. This, on its side, guards the information and along with the team reaches the company s goals, optimizing scheduled pauses which, alongside the predictive maintenance follow, reaches a good ratio, better seen on the table below. 7
Manutenções da unidade fabril - 2009 Corretiva 1,8% Melhorias; 13% Lubrificação 4% Preditiva; 55% Preventiva; 26% 4. CONCLUSION Picture 2 Maintenance types This system took around one and a half year to be fully used. Today there is a control man/time, the maintenance are separated by Preventive, predictive, Improvement and Lubrification, stalled equipment statistics, machinery efficiency, tendencies and execution plans. The investments were only the development hours from the automation engineer and his maintenance supervisor/engineer for the system s implementation, nevertheless, the purchase of machinery and training for the functionaries was vital. The result was quick regarding the maintenance cost control in the last months, before and after the system s implantation, the comparison came as a 35% saving to the company s organization, according to the Chief Executive Officer. Another important observation is that the company possesses another unit in São Paulo and it is implementing one more in Três Lagoas, Mato Grosso do Sul. With an integrated system, the companies can exchange experiences, verify spare parts in local warehouses, among other relevant information of the areas. According to Albertin (2004) by using current technologies, all systems can be interlinked, expediting contracts, information, reports in many parts of the world, this last option, making the companies working, basically, with manual and craft resources. In the past, all the information were delivered by the conventional messengers and, when it was necessary to inform a unit in another country, these information took a long time, weeks even months until they reached their destination. Different from today, because with a simple e-mail, the information are transferred from one place to another in minutes; in the multinational case, the branches easily communicate with their matrix, as mentioned in this article. 8
This company is located in Ponta Grossa and its productive information are destined to the matrix located in Switzerland or, to any part in the world showing an effective use of technology, in other others, of IT (data processing). 5. REFERENCES ALBERTIN, A. L; ABERTIN, R. de M. Tecnologia de informação. São Paulo: Atlas, 2004. ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS ABNT. NBR ISO 14001: sistemas de gestão ambiental. Rio de Janeiro: ABNT, 2004. CAMPOS, C. A. O. Uma proposta para a integração de sistemas de gestão. 2006. 139f. Tese (Doutorado em Engenharia de Produção) Universidade Federal de Pernambuco, Recife, 2006. KARDEC, A.; ARCURI, R.; CABRAL, N. Gestão estratégica e avaliação de desempenho. Rio de Janeiro: Qualitymark, ABRAMAN, 2002. KARDEC, A.; FLORES, J.; SEIXAS. Gestão estratégica e indicadores de desempenho. Rio de Janeiro: Qualitymark, ABRAMAN, 2002. KARDEC, A.; LAFRAIA, J. R. Gestão estratégica e confiabilidade. Rio de Janeiro: Qualitymark, ABRAMAN, 2002. SOUSA Jr., J; CAMPELLO DE SOUZA, F. (Org.) Capitulo: Manias e modas gerenciais. Tópicos em Engenharia de Sistemas. vol. 1 Recife UFPE, 2004 9