The best time to address a big problem is when it is small. Constant monitoring of equipment wear-out based on manufacturers’ requirements and experience coupled with on-site operator inspections and comprehensive maintenance planning features in Apex enables you to develop a proactive response to prevent breakdowns which result in loss of production. It focuses on quality to extend the life of your capital investments and improve your machine availability. It provides a complete framework to plan, prioritize, schedule, and track maintenance. It manages all elements of maintenance including people, spare parts and processes with the associated costs. The system provides data and information to continually improve maintenance processes with a view to increase productivity and effect savings in planned and unplanned maintenance costs.
Apex Plant Maintenance comprises of the following modules:
- Equipment Bill of Material
- Plant Locations
- Maintenance Task Lists
- Maintenance Work Centres
- Maintenance Planning
- Maintenance Scheduling
- Maintenance Processing
Equipment bill of material defines the structure of an asset or assembly. Maintenance task list is a set of operations that are performed on an asset for maintenance. Spares, tools and time required can be assigned to the operations. You can also outsource maintenance operations to a third party. Maintenance work centers comprising of machine and human resource capacities are responsible for executing maintenance tasks.
Maintenance planning is carried out on the basis of manufacturer recommendations and legal and environmental requirements. Counters in the system track asset usage, document asset condition at a particular time and generate alarms when pre-defined limits are crossed. Maintenance tasks that are performed on regular intervals can be defined in the system. Maintenance actions like inspection, lubrication, calibration, replacement etc. form the basis of maintenance orders and you can assign reasons like preventive, breakdown, modification etc. to these actions.
Maintenance plan is the key element in preventive and predictive maintenance and contains scope of tasks with relevant scheduling information. The plan also specifies what needs to be done if a scheduled task is missed for any reason. Maintenance plans are defined on the basis of counters, repetitive maintenance tasks, maintenance actions, reasons and asset criticality. High, medium, low or normal ratings can be assigned to maintenance plans depending on asset criticality. You can also define maintenance plans for complex maintenance cycles.
Maintenance plans form the basis of scheduling planned maintenance for assets. The system supports a comprehensive scheduler to check and create planned maintenance orders for assets that are due for maintenance. The outstanding work is rolled forward and added to the list of outstanding work. Scheduling is carried out in accordance with a set of priority rules – high priority work scheduled first. It optimizes maintenance work with available resources by minimizing wait times for permits, tools, heavy equipment and crew availability.
The notifications record, process, and manage different types of information. Notifications are used to process complaints, maintenance requirements and document malfunctions or exceptional situations. These can also be used to process inquiries and needs. Some of the notification types supported are maintenance notifications, quality notifications, service notifications, change notifications and feed back notifications to properly categorize information and ensure that they are assigned to the proper person or department for further processing.
Apex generates maintenance order for preventive, breakdown or ongoing maintenance tasks. You can create an order with or without reference to a notification. It is possible to assign the order to one or more notifications. An order will normally contain all relevant information like task lists and the spares and tools required for performing maintenance. Documents and drawings of equipment can also be attached with maintenance orders. Completions can be used to ascertain progress on orders. Repairable spares can be refurbished many times for defects or wear, and then made available again as spare parts. Refurbishment orders are used to contract a work center to restore malfunctioning repairable spares to full working order at a certain date. A comprehensive history of all maintenance activities is recorded in the system which forms the basis for predictive maintenance and is also used for analysis.
Salient features of Apex Plant Maintenance are:
- Maintenance planning and scheduling
- Hierarchical plant structures
- Hierarchical equipment structures
- Spares planning
- Automated notifications & reminders
- Comprehensive maintenance history
- Where Used Lists for spares, tools, work centers
- Engineering change management
- Reduced on hand inventory of spares
- Resource and material availability checks
- Auto generation of recurring maintenance orders based on calendar intervals & meter readings
- Track Asset relocations
Apex Plant Maintenance is fully integrated with material management, financials, sales and distribution, human resource management and production modules.