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1 FTM – Fault Tree Maintenance An Online Maintenance Management System Presents.

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1 1 FTM – Fault Tree Maintenance An Online Maintenance Management System Presents

2 2 Simplify your work flow for better management Get information on % Breakdown, MTBF and MTTR Increase all Opportunity maintenance jobs, be Proactive Enhance the power of PM Make TPM a part of your life Monitor machine wise consumption of Spares Strengthen Resource Management and Cost control Helps in monitoring your Utility Equipment Useful for ISO / QS / TS and reduces audit preparations System deployment is swift and smooth FTM will help achieve your Primary Objective of Eliminating Stoppages due to Maintenance using the Fault Tree Technique System Overview

3 3 Productivity being directly hampered because of Breakdowns Repetitive problems decreasing the overall efficiency of Machines Not realizing the full potential of TPM philosophy – Kaizens, Jishu Hozen, 5S, etc. not being implemented practically on a long term basis Not able to correctly quantify planned v/s unplanned maintenance jobs Non-compliance to Preventive Maintenance schedules Doubts in Reliability of all Corrective Maintenance jobs Lack of proper Spares Management increasing cost of Maintenance Time being spent by Maintenance before Audits due to improper documentation Not able to set Performance Measurement Benchmarks and targets to improve upon Maintenance operations Business Concerns related to Maintenance These could vary from Plant to Plant based on the Manufacturing setups

4 4 The FTM Solution focuses on … Improving Production Uptime - By monitoring % Breakdown, MTBF & MTTR Root Cause Failure Analysis too help in eliminating repetitive failures Applying the basics of TPM philosophy pertaining to Maintenance Quantifying Maintenance work orders for resource planning Making PM simple and dynamic so as to comply to schedules Reliability of work to enhance Plant Health Operating Costs by providing Spares Consumption, Inventory Management and Repairs Management Creating proper Performance Benchmarks to measure Maintenance effectiveness Providing Analysis to assist in applying Continuous Improvement measures Maintaining Effective and Timely Documentation Quantify your work to enhance Operations !

5 5 RCM - Reliability Centered Maintenance CBM - Condition Based Maintenance TBM - Time Based Maintenance RCFA - Root Cause Failure Analysis CIP - Continuous Improvement Processes This will help in realizing Total Plant Reliability (TPR) This Focus will help achieve

6 6 One excellent feature of the system is to adapt to the needs of the culture of the organization. This starts with using the same terminologies being used in the plant such as, Equipment or Machine or Tag No. Section or Workshop or Line or Channel or Cell Production Division or Building or Unit or Plant Job Request or Work Order or Work Request … So on and so forth … and Multi-Lingual as well!!! During Startup FTM can be configured to use your Terminologies!!! User Defined Terminologies

7 7 The Offline Mode of Entry In an Offline mode of data entry, the maintenance users do the Job entries on their own. Then, based on the availability of time, these Jobs will be entered in FTM say, at the end of the Shift or Day or Week or even at the end of the Month. The Online Mode of Entry In an Online mode of data entry, the Production users will Log onto FTM through the Ftmweb module and send a request to Maintenance for attending a Job. On the Maintenance users Pending Jobs screen a small screen will be popped up to tell him that a new job has arrived which he then can see in his Pending jobs list. Workflow Management in FTM

8 8 B/D Breakdown Jobs PRTLPartial Breakdowns OPRTOpportunity Maintenance Jobs SERVService Jobs MISCMiscellaneous Jobs PMPreventive Maintenance Jobs ABPMActivity Based PM REPRSRepairs of Spares CBInstrument Calibration R/MReconditioning & Modifications …and others Jobs Affecting Production (Downtime Jobs) Jobs Not Affecting Production (Zero Downtime Jobs) Various types of Work Orders or Jobs in FTM

9 9 Prodn. Divn. 3 Factory Prodn. Divn. 1 Prodn. Divn. 2 Section 1Section 2 Machine 1 Machine 2 Attached Documents 4 Level Machine Breakup Specific Spares Instruments & Gauges B/D PRTL OPRT SERV PM / ABPM REPRS MISC (User Defined) CB Jobs Affecting Production Jobs Not Affecting Production Your Factory and Work Management Your SetupWork Management

10 10 B/D PRTL OPRT SERV PM / ABPM REPRS MISC (User Defined) CB Man Power Spares Internal External Consumable Recyclable Or Repairable The Fault Tree Fault Nature Fault Code Cause Cause 1 Cause 2 Work & Resource Management Work ManagementResource Management

11 11 Developing a Centralized Knowledge Base Streamlining the Workflow & Quantifying your Work Improving PM, Proactive Jobs & Condition Monitoring Utility Equipment Monitoring Optimum Utilization of Resources Effective & Timely Documentation Realizing Total Plant Reliability In short the system focuses on …

12 12 This is mapping of your Department functioning on your Plant. Do you have a Centralized or Distributed Maintenance Setup, i.e. Who is looking after which area of the plant? How your Trade departments or Disciplines (Mechanical, Electrical, etc.) are handling their Jobs. How many Log Books do you maintain? This will help you in mapping your activities in the FTM Work flow and thus help in streamlining your work Maintenance Functionality

13 13 SKF Bearings Group Tetra Pak India Sandvik Asia Coca Cola India Bosch Group ThyssenKrupp Steels Alstom Power Asahi Float Glass Legrand Switchgear Seco Tools Elecon Engineering Cipla Pharmaceuticals Group And various others forming a base of over 40 Installations ! Some of our Clients in India

14 14 % Breakdown % Breakdown (With % of Money Lost) Machine History Summary with MTBF Breakdown Analysis & MTTR Pareto Analysis Fault Tree Analysis Breakdown Analysis Review Spares Consumption Analysis List of Pending Jobs Resource or Manpower Summary PM Schedule & Master Checklist PM Checklist (Pending) Some of the Reports

15 15 NOTE : There are overall 3 to 4 formats for the % Breakdown reports, % Breakdown

16 16 % Breakdown (With % of Money Lost)

17 17 NOTE : This is available Section wise and Machine wise Machine History Summary with MTBF & MTTR

18 18 NOTE : This is available at Plant Level, Section Level & Machine Level Breakdown Analysis & MTTR

19 19 NOTE : This is available at plant Level, Section Level & Machine Level Pareto Analysis

20 20 NOTE : For All Sections, Particular Section, Particular Machine, Fault wise, etc. Fault Tree Analysis

21 21 Breakdown Analysis Review

22 22 NOTE : This is available Spare Part wise, Section wise or Machine wise Spares Consumption Analysis

23 23 List of Pending Jobs

24 24 Resource / Manpower Summary

25 25 PM Schedule & Master Checklist

26 26 PM Checklist Pending

27 27 Contact Information Werardt Systemss Pvt Ltd Pune, India Phone : 91-20-25285256, 25285257 Website : email:

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