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1. 導入資訊管理系統對設備保養管理之影響 The Impact of Implementing MIS on Maintenance Management 報告人﹕游禎平 2007/12/11

2. Management Information System Efrain Turban, R. Kelly Rainer and Richard E. Potter, 2003 • Typically, a functional MIS provides periodic reports about such topics  operational efficiency(經營效率)  effectiveness (效益)  productivity (生產力) • It prepares the reports by extracting information from the corporate database and processing it according to the needs of the users (依據使用者需要從公司的資料庫萃取產生報表)

3. Table of Contents 1.Introduction: Maintenance Management 2. Development of Computerized maintenance management system (CMMS): Procedure, Structure,Tool 3. CMMS Application and Evaluation: Case study 4. Conclusions and Directions for Future Research

4. Table of Contents 1.Introduction: Maintenance Management 2. Development of Computerized maintenance management system (CMMS): Procedure, Structure,Tool 3. CMMS Application and Evaluation: Case study 4. Conclusions and Directions for Future Research

5. 1. Maintenance Management 故障保養 預防保養 生產保養 全員生產保養 預知保養 全員生產管理

6. 2.Maintenance/asset management strategy Maintenance/Asset Strategy (保養策略) Continuous Improvement (持續改善) Total Productive Maintenance Financial Optimization Preventive Maintenance Operations Involvement Reliability Centered Maintenance Stores and Procurement Work Flow System CMMS/ Enterprise Asset Management Technical and Interpersonal Training Productive Management(生產管理)

7. Table of Contents 1.Introduction: Maintenance Management 2. Development of Computerized maintenance management system (CMMS): Procedure, Structure,Tool 3. CMMS Application and Evaluation: Case study 4. Conclusion and Directions for Future Researches

8. Computerized Maintenance Management System 稽核 訓練 組織 計畫 時程 診斷 標準 設備履歷 控制報表

9. Objectives 1. To reduce equipment breakdown. (降低設備故障) 2. To promote productive efficiency. (提升生產效率) 3. To reduce equipment maintenance cost. (降低維修成本) 4. To reduce inventory cost and achieve reasonable inventory (service level). (降低備品庫存) 5. To build knowledge management, troubleshooting technique and repair experience can share. (建立故障檢修知識庫) 6.To develop human resource, promote(開發人力資源) maintenance technical personnel efficiency.

10. 1. Structure of Maintenance Management System ActiveX Controls e.g., RSView, VB machine PLC ControlSystem data collection web-based report Reporting Link (communication tool) Reporting data collection Production Server CMMS Client Reporting Reporting data collection Database (SQL Server or Oracle)

11. 2. Procedures of Maintenance Management System (1). Definition HMI SCADA.(定義人機介面) (2). Build equipment maintenance database. . (建立設備保養資料庫) (3). Computerized maintenance management system. (設備保養管理電腦化) Then, System evaluation and analysis.

12. (1) Definition HMI SCADA • The software about HMI, it designed for manufacturing efficiency, convenient operation and production quality, etc. • HMI is very useful, and we can define the HMI for equipment maintenance by technician also. • The HMI has many brands. There are many software available. This research adopts RS-view which is made by Rockwell Automation Company.

13. (1) Definition HMI SCADA

14. (1) Definition HMI SCADA Define Tag Number ( Mapping PLC address) Build Graphics Modify Graphics

15. (1) Definition HMI SCADA

16. (1) Definition HMI SCADA

17. (1) Definition HMI SCADA

18. (2) Build equipment maintenance database

19. (2) Build equipment maintenance database

20. (3) Computerized maintenance management system DEMO

21. Make decision for maintenance period by supervisor When Equipment breakdown Preventive maintenance Supervisor detach repair job with worksheet (by manual) Look up for troubleshooting by technician Maintenance activity Technicians make notes in worksheet For instance: fault describe, labor and materials Supervisors write ponders able fault to paper, collect to equipment’s curriculum vitae document. (can not analysis real-time) Store up maintenance document for reference, by future troubleshooting Supervisors refer to equipment’s curriculum vitae document. Make decision to maintenance policy. For instance: decision period, replacement, training, inventory, and efficiency. MMS in the past (1992~2002) 設備故障 主管派工 進行維修 填寫紀錄 重點轉記 文件歸檔 保養履歷

22. Analysis from DBMS by computerized HMI definition When Equipment breakdown Preventive maintenance Predicative maintenance Supervisor detach repair job from MIS print worksheet, technician make equipment's rounds of inspection. Reference from DBMS Maintenance activity Technicians make notes in worksheet For instance: fault describe, labor and materials Supervisor/ technician entry notes to maintenance management system database. Automatic transfer to maintenance document in database for reference, by future troubleshooting Supervisor refer and analysis from database. Make decision to maintenance policy. For instance (decision period, replacement, training, inventory, and efficiency) Develop new CMMS (2004) 機台自動蒐集故障訊息 建立資料庫 ,方便就源輸入!!

23. E-R diagram for maintenance management database

24. Maintenance Management Database DEMO

25. Table of Contents 1.Introduction: Maintenance Management 2. Development of Computerized maintenance management system (CMMS): Procedure, Structure,Tool 3. CMMS Application and Evaluation: Case study 4. Conclusion and Directions for Future Researches

26. The background of case study • This thesis collects seven months, November 2004 to May 2005, electrical equipment fault event data from a chemical manufacturing firm, about 3200 jobs being analyzed. • The case study company, an ISO9001 and ISO14000 certificated company, produces polyester fiber. • The company was established in October, 1967, and is a full-processing manufacturer of polyester filament and staple fiber. • In terms of capacity, the case study company is the second largest polyester producer all over the world, and is number one in Taiwan.

27. Access supports a variety of query types (Access 支援各種查詢功能) • These queries return data from one or more tables and display the results in a result table. • The table is updateable, which means that we can change the data in the table and the changes will be reflected in the underlying tables. • Selected queries can also be used to group rows and calculate sums, counts, averages, and other types of totals for these groups.

28. Search from maintenance management database for estimating same equipment troubleshooting times.(估計相同設備異常次數) /*Access SQL language */ SELECT [Factory], [System], [Machine], [Date], [Fault describe] FROM search MMS duplicate WHERE [Factory] In (SELECT [Factory] FROM [search MMS duplicate] As Tmp GROUP BY [Factory],[System],[Machine] HAVING Count(*)>1 And [System] = [search MMS duplicate].[System] And [Machine] = [search MMS duplicate].[Machine]) ORDER BY [Factory], [System], [Machine]; /*END*/

29. Establish maintenance cycle

30. Search database forecasting equipments fault from MMS (預測設備相同異常次數) /*Access SQL language*/ The SQL SELECT MMS.Date, MMS.[Fault describe], MMS.Factory, MMS.System, MMS.Machine FROM MMS WHERE (((MMS.Date) In (SELECT [Date] FROM [MMS] As Tmp GROUP BY [Date],[Fault descript] HAVING Count(*)>1 And [Fault descript] = [MMS].[Fault descript]))) ORDER BY MMS.Date, MMS. [Fault descript]; /*END*/

31. Fault analyses for maintenance strategy

32. Search from MMS database for estimating equipment troubleshooting job that needs unspecified inventory (預測設備相同元件損壞頻率) /*Access SQL language*/ SELECT [MMS SEARCH COMPOENT]. Component, [MMS SEARCH COMPOENT].[Job No], [MMS SEARCH COMPOENT].Date, [MMS SEARCH COMPOENT].Factory, [MMS SEARCH COMPOENT].System, [MMS SEARCH COMPOENT].Machine, [MMS SEARCH COMPOENT].[Maintenance Note], [MMS SEARCH COMPOENT].Analysis, [MMS SEARCH COMPOENT].Strategy, [MMS SEARCH COMPOENT].Classifies FROM [MMS SEARCH COMPOENT] WHERE ((([MMS SEARCH COMPOENT].Component) In (SELECT [Component] FROM [MMS SEARCH COMPOENT] As Tmp GROUP BY [Component] HAVING Count(*)>1 ))) ORDER BY [MMS SEARCH COMPOENT].Component; /*END*/

33. Analysis of maintenance material requirement DEMO

34. Inventory Management Database DEMO

35. Factory equipment breakdown ratio

36. Comparisons of breakdown ratio, with/without CMMS

37. Comparisons of factory maintenance fees, with/without CMMS

38. Comparisons of all factories maintenance fee with/without CMMS

39. 3. Knowledge Management

40. Knowledge Management Database

41. Evaluate CMMS for Knowledge Management DEMO

42. Evaluate CMMS for Knowledge Management • CMMS can also function on sharing KM maintenance knowledge, which has never been measured by computer before. • The hands-on experience sharing has rapidly enhanced the technician’s ability, resulting in 4 out of 72 workforce being saved. • The cost for cultivating a technician is about NT$68,000/per month; the adoption of CMMS system has saved NT$ 272,000/per month for the case study company.

43. Apply this CMMS to link MIS of enterprise. We perform maintenance management well. Refer to the following description: 1. Define Maintenance Tasks(定義保養工作) 2. Plan Maintenance Work(計畫保養工作) 3. Update Work Order(更新派工) 4. Get Work Done in a Certain Period(限定完工期限) 5. List of Parts Re-Ordered(庫存備品採購) 6. For Conducting Training(員工訓練)

44. Table of Contents 1.Introduction: Maintenance Management 2. Development of Computerized maintenance management system (CMMS): Procedure, Structure,Tool 3. CMMS Application and Evaluation: Case study 4. Conclusions and Directions for Future Research

45. 4.1 Conclusion • The goal of maintenance activity is to provide high quality, low cost maintenance. (達成高品質低成本的目標) • A good maintenance management will definitely reduce productive loss. (可減少生產損失) • Adoption of CMMS enhances the performance of maintenance, inspection, monitoring, inventory, and training, etc. (採用電腦化維修管理可以增強保養執行) • By integrating with Enterprise Resources Planning (ERP) or MIS, we can perform better to maintenance management. (採用電腦化維修管理方便與MIS整合) • CMMS, predictive and maintenance tracking systems are now a necessary in managing and controlling assets, plant and equipment maintenance in modern manufacturing. (採用電腦化維修管理對現代製造業是必須的)

46. 4.2 Directions for Future Researches • Re-manufacture, repair, and exchange services for equipments and reliable parts; repair the third party’s parts (low cost) and evaluate the using validity. (開發對抗品,低價位可靠的備品) • Reduce the associated costs on site management of parts inventories, and increase working time to ensure that users have the right replacement parts. • (降低維修備品成本) • 3. Combine CMMS systems with the existing or planning control systems to increase real-time monitoring capabilities. (結合CMMS增強即時監視能力) • 4. Remote diagnostic services to increase facility uptime and reduce overall labor expenses. (遠端維修減少人力浪費)

47. 4.2 Directions for Future Research 5. Consult professionals and expertise to implement EAM solutions without developing additional in-house expertise. (委外顧問及專家) 6.Establish the predictive maintenance practices, which display more effective than that of breakdown maintenance techniques. (建立預知保養執行) 7.  Ensure all HMI will automatically transform to maintenance management database, in order to achieve real-time trusty. (HMI自動轉換到維修管理系統) 8.Maintain Database for data security. (database維護及安全)

48. Thanks and giving suggestions