What is a Plant Maintenance System?
Plant maintenance systems involve the use of CMMS software, however a maintenance system is more than your basic work order program. Our time-proven plant maintenance system provides many analysis and reporting tools needed to effectively monitor and improve your manufacturing plant equipment.
First of all, our reporting capabilities set the bar very high with Crystal Reports, OLAP (online analytical processing), data cubes, drag and drop report building and more. Secondly, our analysis capabilities are unmatched in any other plant maintenance solution. Overall equipment effectiveness and reliability analysis are two of the powerful tools in the MaintSmart toolbox. Without a doubt, our analysis and reporting capabilities improve your maintenance efficiencies and equipment reliability leading to dramatic cost savings in lost production time.
Benefits of Overall Equipment Effectiveness Software (OEE Software)
A common complaint we hear from plant maintenance system users looking a purchasing our product is that their old CMMS contained a lot of data, however it was difficult or impossible to use the data due to poor reporting and analysis features. Our plant maintenance system offers simple ways to always analyze and report on ALL data in the system. A useful example of this is how our software system leverages downtime data into OEE reporting.
OEE (overall equipment effectiveness) is derived from the downtime data providing a valuable KPI. Actually the OEE roll-up KPI is composed of three (3) important KPI values:
- Equipment performance
- Product quality
Availability is the operating time/planned production time. This takes into account losses due to equipment failures. This plant maintenance system has a dedicated downtime (equipment failure) tracking system. This system provides the necessary data for the overall equipment effectiveness component. Another often overlooked source of availability loss is changeover time. This is time that could otherwise be used for production and should be accounted for.
Quality is defined as Good Pieces Produced/All Pieces Produced. Normally you may not consider quality to be a maintenance management issue but good running equipment produces better quality product generally speaking. Therefore quality is included in the overall equipment effectiveness KPI. More often the quality losses are a result of start-up losses, changeover losses and possibly improper speed settings by equipment operators. These should all be considered but may be beyond the control of the maintenance manager.
Equipment manufacturers define a Ideal Equipment Run Rate (Ideal Cycle Time). An example for a bread divider (cuts dough balls to form a bread loaf) might be 200 loaves/minute. This is the design cycle time. Whether this rate is accomplished is dependent upon several factors. However a poorly running equipment item typically results in a poorer performance overall equipment effectiveness KPI.
Where to Implement OEE?
Collecting CMMS program data for the purposes of overall equipment effectiveness analysis should begin with equipment bottlenecks on the production line. This metric is sometimes referred to as the constraint. The line or process is limited by this bottleneck so there is no point is monitoring all the equipment on a line. If the bottleneck is resolved then find the next bottleneck and monitor it. In similar fashion, continue this process until all relevant bottlenecks are resolved.
How to Collect OEE Data (Downtime)
To be of any use, good data must be used for OEE and it's component parts. Plant maintenance system data from the downtime data table is an integral part of the overall equipment effectiveness data collection process. Downtime data is entered manually or imported from the downtime data table into the overall equipment effectiveness analysis function. Obtaining the Quality parameter needed for OEE is fairly straight forward. That being said, care should be taken not to include re-worked product that was initially rejected. The Performance KPI requires an Ideal Run Rate and the Planned Production Time. Planned production time is the scheduled production run time less breaks of any type other than unplanned downtime.
How Do We Rate with OEE?
The typical OEE value for manufacturing is in the 60% range. World class OEE values are above 80%. In other words, many of these typical manufacturing plants could improve dramatically by implementing OEE. Identifying bottlenecks and correcting these issues with OEE as a guide leads to more reliable equipment operation. With this plant maintenance system all the tools needed to correct and improve are available in the base module. These tools include extensive down time analysis, a powerful query-builder, multiple reporting methods and military standard reliability analysis.