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Asset Optimization Solutions. Asset Optimization Solutions Will Help to identify and Improve the true Potential of existing Plant and Machinery.

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Presentation on theme: "Asset Optimization Solutions. Asset Optimization Solutions Will Help to identify and Improve the true Potential of existing Plant and Machinery."— Presentation transcript:

1 Asset Optimization Solutions

2 Asset Optimization Solutions Will Help to identify and Improve the true Potential of existing Plant and Machinery

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4 Not getting the desired output from every Production assets due to unplanned Downtime Discrepancy in Design v/s Actual output from Production assets Cannot realize full ROI on Investments made in Production assets Data collected on the Shop floor not helping on proper Analysis to apply improvement measures Unexplainable Delivery failures due to lack of authentic data Availability, Rejection & Productivity not being appropriately measured so as to arrive at daily OEE across the plant Figures such as OLE and OPE not available due to lack of correct data Not able to apply TPM principles to help in CIP (Continuous Improvement Programs) to optimize on Asset Utilization for Production Business Concerns related to Production

5 ERP MES Field Controls The MES Overview

6 MES System Machine Stoppage Data Options Data File Counter Data File HMI P.B. Panel Production Data Options PLC in case of H/W Interfaces OR System Architecture

7 The MES Solution A comprehensive Production MIS covering various reports required for standardization of information outputs An Integrated System to help in reducing Data Redundancy and provide Authentic data from the system on a regular basis Data can be captured either manually or through electronic interfaces with the Machines, if possible A Scalable application considering the future growth of the Organization making it compatible to TPM ideology

8 The MES Solution Will help to save on… - Time to analyze the daily production data. - Time to analyze the daily Rejection data - Time to analyze the daily Production Lost time Data And will also provide OEE, OLE and OPE figures Will help to reduce the response time in analyzing the data and thus lead management in taking timely action wherever required Offers data Security at multiple levels of Management Standardize the reporting system for all the Sections and Machines throughout the organization

9 The MES Solution Store Production Data in a Database Server instead of discrete files to minimize the risk of Data loss Objective based Implementation will help to successfully deploy the system in your Organization Is closely integrated with our existing FTM System as part of your daily workflow MES is fast to Deploy & Easy to use !!!

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11 Productivity being directly hampered because of Breakdowns Repetitive problems decreasing the overall efficiency of Machines A lot of time being spent by Maintenance before Audits due to lack of proper records being maintained Lack of proper Spares Management increasing cost of Maintenance Non-compliance to Preventive Maintenance schedules Not able to correctly quantify planned v/s unplanned maintenance jobs Doubts in Reliability of all Corrective Maintenance jobs 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 set Performance Measurement Benchmarks and targets to improve upon Maintenance operations Maintenance being demoralized due to criticism by everyone in spite of extra hours being spent in the plant Business Concerns related to Maintenance

12 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 & Work Management The Factory

13 Work Management 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 Resource Management

14 The FTM Solution focuses on … Improving Production Uptime - By monitoring % Breakdown, MTBF & MTTR Plant Health & Operating Costs Machine-wise Maintenance Cost - By getting Spares and Manpower cost Effective Spares Management Effective Repairs Management – Track the Recycling of Spares Root Cause Failure Analysis by eliminating repetitive failures

15 The FTM Solution focuses on … Developing a Centralized Knowledge Base Streamlining the Workflow & Quantifying your Work Improving PM, Proactive Jobs & Condition Monitoring Optimum Utilization of Resources Effective & Timely Documentation Realizing Total Plant Reliability

16 The FTM Helps to Achieve RCM - Reliability Centered Maintenance CBM - Condition Based Maintenance TBM - Time Based Maintenance RCFA - Root Cause Failure Analysis CIP - Continuous Improvement Processes FTM is fast to Deploy & Easy to use !!!

17 Contact Information Werardt Systemss Pvt Ltd Pune, India Phone : , Website :


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