Integrated Manufacturing Information System

Defence Research & Development Laboratory, Hyderabad

COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM

BY

G.SAI LAKSHMI (07D01A0599)

K.AMUKTHA( 07D01A0564)

CH.UDAYALAKSHMI (07D01A05B5)

•Machine history

•Online breakdown requisitions

•Preventive maintenance planning and scheduling.

•Spares and inventory management

•Fault analysis Knowledge Based system

•Reports

Project Goals

MASTER INFORMATION(M/C parameters)

BREAKDOWN MAINTENANCE

MACHINE REINSTALLATION,

UPGRADATION, RETROFITTING

PREVENTIVE MAINTENANCE

M/C HISTORY

Modules in the system

CMMS MENU STRUCTURE

REPORTS

LOCATION

BAY LOCATION

MACHINE TYPE

M / C CATEGORY

VENDOR DETAILS

MACHINE LIST

MAHINE CHECK LIST

SPARES

COMMON SPARES

INSTALLATION & COMMISSIONING

REINSTALLATION

UPGRADATION

RETROFITTING

BREAKDNREQUISITON

BREAKDNREQUISITION LIST

BREAKDOWNACTION

FAILURE ANALYSIS DATABASE

PREVENTIVE POOL

PREVENTIVE PLAN

MACHINE HISTORY

BREAKDOWN HISTORY

PREVENTIVE HISTORY

CONTROL REGISTER

BREAKDOWN

PREV.PLANPREV.CHART

MASTER MACHINE BREAKDOWN PREVENTIVE HISTORY EXIT

Online Requisition, action, breakdown requisition list.

Spares and inventory management.

Machine history.

Machine downtime calculation.

Fault analysis knowledge based system.

Procurement Planning.

Work schedule

Implemented security by assigning roles to user.

Features implemented

LINK OF ACTIVITIES IN CMM SYSTEM

MACHINE PARAMETERS

INSTALLATION

REINSTALLATION

UPGRADATION

RETROFITTING

SPARES INVENTORY

TEAM DETAILS

VENDOR DETAILS

WORK SCHEDULE

PREVENTIVE MAINT

BREAKDOWN MAINT

PROCUREMENT PLAN

DEMAND REFERENCE

BUDGET

REQUIRES

REQUIRES

REQUIRES

UPDATES

REQUIRES

UPDATES

REQUIRES

REQUIRES

UPDATES

HISTORYREQUIRES

NEW INSTALLATION

• Machine type, Category, Make, Model, Status, Procurement details

Location details, Installation dates, Electronics Details, Feedback

Details, Mechanical Details, CNC Details, Oil Details

RE INSTALLATION

• Changes in Location,Bay, Sequence, Power Panel no, Operator

details

UPGRADATION

• Procurement details and upgraded items, type, quantity.

RETROFITTING

• Procurement details and retrofit items, type, quantity.

YES

RECORD IN CONTROL REGISTER & ALLOT CONTROL NUMBER

MAINTENANCESERVICEREQUISITION

CONTROLREGISTER

1. CONT.REG.

HAND OVER

REPAIRED

MACHINE

CONDEMNTHE MACHINE

1.CONT.REG.2.M.S.R3.BREAKDOWN4.HISTORY CARD

ROLE OF CMMS S/W IN BREAKDOWN MAINTENANCE PROCESS

ONLINE MAINTENANCESERVICEREQUISITION

M/C STATUS = BREAKDOWN

RECEIVEREQUISITION

NOT AVAILABLE FOR SCHEDULING

NO

THE SOFTWARE GENERATES CONTROL NO

AUTOMATICALLY AND DETAILS ARE ENTERED

INTO THE DATABASE

FAULT

ANALYSIS

KNOWLEDGE

BASED DB

TASK TEAM FORMATION

MACHINE / COMMONSPARES LOOKUP

ALLOT WORK

CARRY OUT PRELIMINARY CHECKS ASSESS

COMPLEXITY

STUDY PROBLEM

BREAKDOWN SPARES

IN HOUSECOMPLIANC

ESPARES

RECORD WORK AND REASON FOR FAILURE

PURCHASE SPARES OUTSIDE CONTRACT/ SERVICES, UPGRADE

MACHINE

POSSIBLEREPAIR/

UPGRADATION

CARRY OUT

REPAIR UPGRADE

ENTER RESONS FOR FAILURE AND ACTION TAKEN

STATUS = WORKINGSCHEDULABLE

CLOSE REQUISITION

NO

YES

MAINT.CHART

MAINTENACE PLAN

RESCHEDULE

CARRY OUTMAINTENANCE

HAND OVERMACHINE TO

SHOP

REVISEDMAINTENANCE

PLAN

1.CHECK LIST2.MAINT.PLAN

SCHEDULEMAINTENANCE

CHECKAVAILABILITY

PREPAREMAINT. PLAN

RECORD DETAILS

REVENTIVE MAINT POOL

SHOP FLOORFEEDBACK

ON PREV MAINT

SOFTWARE ACTIVITY/ FACILITY

MAINTENANCE ACTIVITY

ROLE OF CMMS S/W IN PREVENTIVE MAINTENANCE PROCESS

•Following details are maintained

New installation

Breakdown,

Preventive maintenance

Reinstallation

Upgrade

Retrofitting

•Machine downtime is calculated in days basing on breakdown history

MACHINE HISTORY

ROLES

PROCESS

USERINSTAL

RETROFIT REINSTAL UPGRADE.

BREAK DOWN REQ.

BREAK DOWN

ACTION

PREV.

PLAN

PREV.

CHARTVIEW

SHOP FLOOR

SHOP FLOOR

INCHARGE

MAINTENANCE STAFF

MAINTENANCE

ADMINSTRATOR

ALL USERS

TESTING

1. Check each and every module for proper functioning

 

2. Test for proper insertion, deletion, updation and querying of records.

 

3. Verify the functioning of Triggers, Alerts, Procedures, Cursors and Post-Queries of all the modules.

 

4. The read only attributes of a form are protected against update.

 

5. To check for data integrity and data security.

Forms initiated can be modified by respective persons only.

Authorized access of information.

Generation of work order no.

PERSONAL No.&

PASSWORD

PLANT MAINTENAN

CE

MACHINE DETAILS

MAINTENANCE

WORK PLANNING

INVENTORY

MISCELLANEOUS

Menu Mach

Menu Maint

Menu work

Menu Inv

Menu Miss

PLANT MAINTENANCE

UML DIAGRAM FOR PLANT MAINTENANCE

Machine DetailsINSTALLATION

RE INSTALLATION

UPGRADATION

Sinstb

Srinb

Supgrb

UML DIAGRAM FOR MACHINE DETAILS

UML DIAGRAM FOR MAINTENANCE

MAINTENANCE

MAINTENANCE

BRKDN MAINT REQ

BRKDN MAINT ACT

PREV. MAINT SCHED

PREV. MAINTENANCE

Sbmab

Sbmrb

Spmsb

Spmrb

HISTORY

UPGRADEHISTORY

REINSTALHISTORY

SCREENS

FAILURE ANALYSIS

INSTALLATION

INSTALLATION

Continued…

REINSTALLATION

UPGRADATION

BREAKDOWN MAINTENANCE

REQUISITION

ACTION

PREVENTIVE MAINTENANCE

REPORTS

INSTALLATION, REINSTALLATION, UPGRADATION, RETROFITTING.

BREAKDOWN REQUISITIONS, BREAKDOWN ACTIVITIES.

PREVENTIVE PLAN AND PREVENTIVE SCHEDULE.

MACHINE HISTORY.

BREAKDOWN HISTORY - YEAR WISE AND MONTH WISE.

PREVENTIVE HISTORY - YEARWISE AND MONTHWISE.

FAILURE ANALYSIS KNOWLEDGE BASE.

Milestones

• Retrieved 265 records of machine details from log

files.

• Retrieved nearly 2000 spares records from tables.

• Breakdown maintenance data for year 2003 is entered

into the database

• Preventive maintenance data for years 2001-2003 is

entered.

Benefits

Instant access to machine history and machine downtime.

Failure analysis knowledge base database

for related problem .

Automatic generation of control register.

Machine downtime helps to know the

future of the machine.

Status

• Designed, Developed and Implemented

• Deployment of system at user’s place

• Training has been provided

• System is presently in use