Computerized plant maintenance

Predictive maintenance prevents failures from happening at a bad time and fixes them before they cause damage

The foundation for preventive maintenance information is the equipment records.

Somewhere, there is probably a small organization that still has records on paper, but the vast majority of equipment records should be in electronic databases.

The benefit obtained from computerizing maintenance records is much greater than the relatively small cost. There should be a current data file for every significant piece of equipment, both fixed and movable.

The equipment database provides information for many purposes beyond predictive maintenance (PM), and includes considerations for configuration management, documentation, employee skill requirements, energy consumption, financiáis, new equipment design, parts requirements, procurement, safety, and warranty recovery. Essential data items include:

* Equipment identification number

* Equipment name

* Equipment product/family/group/class

* Supplier(s)

* OEM and supplier model numbers

* Geographic location

* System process location

* Criticality

* Responsible user

* Installation date

* Warranty end date

* Original comprehensive cost

* Current value

* Safety precautions

* Use per day

* Use meter reading (latest plus history)

* PM interval(s)

* Last PM date and meter

* Next PM due date and meter

* PM average time, personnel, and parts

The data for new equipment goes to the computer database immediately. The original purchase order and shipping documents can be the source, with other data elements added as they are fixed. It is important to remember there are probably three stages of configuration:

1. As designed

2. As built

3. As maintained

The as-maintained database is the major challenge to keep continually current. One needs to update the master equipment data as an intuitive and real-time element of the maintenance system. If pieces of paper are used, often, they are forgotten and become obliterated with grease, and the data may not get into the single master location on the computer.

Part number revisions are especially necessary for the rapid reordering of correct parts. A characteristic of good information systems is data should only need single entry and all related data fields will update automatically. Many maintenance applications today are web-based so one can access them from anywhere a computer (or even a personal digital assistant or enabled cell phone) can connect to the Internet.

Investment in data entry

When the first IBM personal computer (PC) came out, it cost $8,500, and a separate 10 MB disk drive was as large as the base central-processing unit. Today, that capability would costs less than $500.

Attitudes toward maintenance use of computers have also changed. The Infor- mation Systems departments struggled to keep strict control of all computers and software in their companies, and maintenance was usually very low on the priority list for assistance.

Now, maintenance organizations have much greater say over what they need and how it should come. Computerized maintenance management systems (CMMS) are now commonplace.

Internet search of just the Plant Maintenance Resource Center finds 320 different software vendors who claim to provide systems for maintenance. PM capabilities are a major element of most CMMS offerings.

Computers are only one component of the information system capability. Data entry is a challenge because big fingers often do not handle delicate electronic keypads well. Do note deciphering the handwriting of many maintenance people may be an even more difficult challenge.

Much PM information is printed on paper since the paper is familiar and easily carried on a clipboard or stuffed into a pocket. Electronic personal digital assistants (PDAs), Blackberry two-way pagers, voice recognition, bar codes, and other technologies are coming to the maintenance teams, often with wireless communications.

A relatively small investment in data entry technology can gain immediate reporting, faster response to discovered problems, accurate numbers gathered on the site, less travel, knowledge of what parts are in stock to repair deficiencies, and many other benefits.

Record info accurately

All work to be done - and what actually is done - on equipment should be recorded on a work order so the data can be electronically transferred to all applicable using programs.

The ability to analyze work order data is critical to guide setting of optimum PM intervals and to detect problems related to too little or too much PM. All the metrics listed earlier can be set in the computer so they routinely undergo analysis and reporting without additional human effort.

Printed information is more useful for some PM personnel who do not easily make the transition to electronic PDAs. Laptop computers can contain all the above information for electronic viewing, but pieces of paper are often easier to carry and handle in difficult surroundings.

A major challenge is to train, coach, and discipline all PM people to record the information accurately at the time of action. A helpful technique is to show maintenance personnel how their accurate reporting results in knowledge and guidance to improve PM and other maintenance operations.