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Base-SI Description
Base-SI - Maintenance and Plant Operation Statistically, about 40 % of the cost of a plants operation account for maintenance and repair. For many plant managers, this is the motive for tracking and controlling their assets and all processes related to maintenance with the help of computers. Software designed for this purpose is commonly labeled as CMMS (Computerized Maintenance Management System). However, these systems may differ significantly in functionality. The Plant Management System SI not only comprises a comprehensive set of CMMSmodules. Instead, SIs full scope goes far beyond a standard CMMS. The SI-system includes a large number of tightly integrated applications that taken together provide a major contribution to the improvement of:
the workflow that has to reflect the plants organization properly, the controlling of the maintenance processes, the conformance to standard procedures, official regulations and laws,
to name only a few. The introduction of such a highly integrated system cant be achieved from one day to the other. On one hand the daily work of the maintenance personnel runs in parallel. On the other hand, some fundamental information must be put together such that other modules can base on them. Therefore, a stepwise introduction to the computerized maintenance management is often preferable to an introduction of a CMMS in one giant leap. For stepwise introduction, certain SI-modules have been bundled to form the package Base-SI. These modules are:
Recurrent Measures, Electronic Log Book (Shift Log), Maintenance Measures incl. the related Workflow and Document Management.
The following figure presents these applications together with the required fundamental modules.
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Base-SI Description
Personal data
Shiftlog
Assignments CT
-ME01 001
ABC
PI
9 LAC10 AP001 -M01 M
TOW WA
TOW: Type of Work Free selection per work area (WA)
Measure
Maintenance
selects selects selects selects Shift leader Shift 4 KWx/S4
Deadlines
Mrz 06 M 6 D 7 M 1 8 D 2 9 F 3 S 4 S 5 3 4 5 6 7 M D April 06 M D F S 1 8 S 2 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 20 21 22 23 24 25 26 17 18 19 20 21 22 23 27 28 29 30 31 Mai 06 M 1 8 D 2 9 M 3 D 4 F 5 S 6 S 7 5 6 7 M D 24 25 26 27 28 29 30 Juni 06 M D 1 8 F 2 9 S 3 S 4
Information
measure is necessary
Author
Autor
create measure
10 11 12 13 14
10 11
KPA02 001
Responsible for Budget Executing person Responsible for Maintenance Responsible for Operations Responsible for Technology Responsible for Work Planning Responsible for Technical Planning Coordination with
Executing Person for TOW Responsible for TOW TOW-Controlling Person TOW-Feedback
15 16 17 18 19 20 21 12 13 14 15 16 17 18
22 23 24 25 26 27 28 19 20 21 22 23 24 25 29 30 31 26 27 28 29 30
Verantwortlicher
acknowledge measure
Author
measure acknowledged
Plant Index
Technical Data
Responsible for Technology Responsible for Work Planning Responsible for Technical Planning Coordination with
Book keeper
Foreman
SI -Infobox
Executing Person
Ausfhrender
Execute measure
Information for
Information for
Roles
Maintenance Schedules Documents
Datum Einsatz
Measure
1239
347 3567
Permit to Work
Controlling
Need more?
Need more?
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Base-SI Description
SIs fundamental and indispensable modules are those that handle the master data. These include:
the Plant Index (which, for example, could utilize the KKS-key), the Registry of all Components, i.e. the complete equipment inventory, the Component Curriculum Vitae and the Plant History, the Component Type Register, referring to Technical Data and Standard Maintenance Plans and
the Address Book along with the Staff Appointment Scheme, showing supervisors, employees and deputies. Two essential concepts of the SI-system are shown in the figure as well:
The concept of Roles and Role Assignments which is used to support a standardized information flow and assignment of tasks in a flexible manner. In the SI dialogs, a user merely specifies a plant index, a component type or type of work. By applying the role assignments that have been configured in the master data, SI automatically deduces responsible and work performing personnel from the given information. Role assignments do not only reflect responsibility assignments in a plant, but also internal standard procedures and individual information paths. The central information dispatch mechanisms provided by the SI-Info box Each individual SI-user exactly receives those pieces of information and those tasks that are destined to him or her, respectively.
Utilization of the role and communication concepts significantly contributes to the fact that the daily work can be executed fast and in a clearly structured way. By granting individual access privileges to SI users the SI administrator makes sure that unintended or unauthorized data access is prevented and individual SI-modules (e.g. Shift Log) are only available to a desired group of users.
What do I want to achieve by using a CMMS system? What are my specific demands of the future data processing system? In detail: which functionalities should the new system provide?
During the introduction phase of a CMMS it is important to pursuit ones most prominent objectives and to always keep an eye on the cost-benefit-ratio. Whatever the priorities of an upcoming SI-user may be: positive effects do always arise during the introduction of an SIsystem as they directly result from assembling the data base needed for the execution of the SI-applications. Examples of objectives:
If the primary objective of a future CMMS user is merely the creation of a well structured technical plant documentation he already completes this task with the comprehensive collection of the plant and component structure and all related technical data and documents. If, however, the objective is not to miss repetitive inspections and maintenance tasks and to record the uninterrupted evidence of all performed inspections and tasks, the creation of
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It is important for the customer that a new SI-system will not be delivered as an empty shell. Instead, it will already contain a large amount of master data providing easy first steps within short time. New customers will become independent from SI-consultants after only a few introductory training sessions and will be able to handle the further buildup of the system with own personnel in a cost effective fashion and adapted to his own needs. SI contains its own privilege administration for the individual applications. Aside from the normal users there is also a special SI-administrator who administers userspecific privileges and should also have a deeper understanding of the SI-system concepts and applications. If desired, this function as well as the supervision of the systems hardware, operating and database system can also be provided by STEAG through remote access.
2.1
Step by Step
We strongly recommend the stepwise introduction of an SI-system, whereas first SIapplications can already be launched immediately after the buildup of the master data.
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SI-Introduction, Phase 1: Collection of Base Data At the beginning of the SI-introduction, it is necessary
to collect the personal data of the future SIusers and their organization in the Staff Appointment Scheme (organigram) to record the Technical Components in a hierarchical structure (can be achieved by simple data import mechanisms).
Phase 1b: If the objective of the SI-introduction is a well structured technical documentation of the plant, the Component Type Index along with related Technical Data as well as the Register of Component Use should be set up or imported (CSV file format) in addition to the plant index and the organigram. Phase 1 is finished now. If desired, the technical plant documentation can be completed by assigning documents to component types or plant indexes (see phase 4).
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2.1.1
The responsibility for this complete plant section bears the job holder machine technology, Mr. Meier. Only if the subsection water treatment is affected, Ms. Schulz is responsible. The general rule is: if there is an electro-technical failure, the (job holder) E-Workshop is responsible. Exceptions are the special actuators of type XY for which Mr. Knorr is responsible.
selects
selects
selects
In general, the execution of all lubrication tasks is assigned to the mechanical workshop. Unless the task has to be performed on a machine in the warehouse in which case Mr. Maiwald is responsible for lubrication, as he is responsible for the whole warehouse. However, Mr. Maiwald doesnt touch the large Ansaldo-machines. This in turn is done by the mechanical workshop.
Instead of having to retrieve responsibility assignments from a persons memory over and over again, It is much more efficient to store these plant internal rules in the database and to apply them automatically, e.g. in relation to a specific components damage or maintenance task. Once it is stored in the database, this wheelwork of assignments can now drive first applications like the Electronic Shift Log or the Maintenance Measures.
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selects
By investigating these assignments, the SI-system finds the responsible and work performing persons e.g. in case of a damage report and informs them automatically!! If larger individual maintenance measures need to be supervised (module Measures) where different persons have to contribute their activities (like ap4proving or authorizing) individual workflows can be defined that also access the stored rules, thus controlling the information mechanism of the SI -Info box. Each SI-user has his own SI-Info box in which he receives all information addressed to him. The information is structured and sorted by topics and comprises a list of all tasks he has to perform. The SI -Info box is superior to a normal e-mail application with respect to work assistance because on one hand the SI-system deduces the receiver of information and tasks automatically from to the prepared rules. On the other hand, the SI-Info box hand provides access to the task dialogs just by double-clicking. You cant be faster!
Measure
measure is necessary
Author
create measure
Responsible Person
acknowledge measure
measure acknowledged
2.1.2
Measure
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KPA02 001
Referencing
PI-Maintenance Schedule StandardMaintenance Schedules for CTI
3. Feedback
1. Request
2. Execute
If there are many components of the same type and the user desires to plan the maintenance tasks in more detail, the Component Type Register should be built up prior to setting up recurrent measures. For a given type of component you can not only add technical data but also create standard maintenance plans. When you set up a recurrent measure, the SIsystem allows you to automatically refer to those standard plans for component types. By assigning components to mounting locations new entries are recorded in the Register of Component Use, the technical inventory of the plant.
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2.1.3
It is about time to focus on the documentation of the plant and the components which may still be spread out. The SI-system supports the storage and management of documents and their relations to components, mounting locations, shift entries, maintenance measures etc. by utilizing a document key.
log
In the SI-system, each document is uniquely identified by a DOKUKey to which a data sheet with characteristic data can be assigned. The document can be linked to maintenance objects and is stored on a document server, to which the SIworkstations have access rights to.
In the ideal case the DOKU-key already tells the most prominent information, whether it is
an operating manual or a schematic pipe drawing for an object in the plant index, a CAD-cross view of a specific component type or
the text of regulations stemming from an authority or a scanned document of the plants permission for erection.
With the associated viewer applications or the full-blown applications (e.g. CAD or office applications), documents can be visualized or modified. The SI-system controls the access to documents depending on a users permissions and keeps track of document versions after modifications.
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Key AVZ
Length 22
BMA
Component Types
ADA
Type of Work
DOHI
DOKU
Document Key
24
Unique name of a document, e.g. a CADdrawing. The key tells the related part a KKS here.
SMS
Gets assigned to a damage report: Expression of the damage Damage symptoms Cause of the damage
With regard to the key systems, new SI users do not have to start with an empty data base. Instead, SI gets delivered along with a large number of preconfigured keys (orgware).
1 Instead of a KKS-key the plant index can also use any other (hierarchical) key system or arbitrary textual identifications.
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Crash
Updates?
Technical and Control Applications: SI Procontrol-P MBS Futura Siemens-TXP SE ... ZEBIS
STEAGs System Services department offers an application server concept, providing a scalable solution which is not only suitable for the operation of an SI-system.
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To Conclude With a decision in favour of the SI-system you choose a plant management system that has accumulated 15 years of experience. The concepts in the SI-system are designed to achieve optimal work time efficiency by supporting the rapid execution of daily tasks of maintenance and plant management personnel. The entrance into computerized maintenance management with Base-SI is extremely efficient because of the included orgware. For the future extension of your Base-SI system a large number of integrated SI applications is available. In the past and also in future SI-system enhancements are continuously led by the demands of customers inside and outside the STEAG group. By choosing the SI-system you choose a plant management system with future! Contact: STEAG Energy Services GmbH Rttenscheider Strae 1 3 45128 Essen, Germany Dr. Martin Stephan E-Mail: martin.stephan@steag.com Tel.: +49-201-801-4109 www.steag-systemtechnologies.com
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