CMMS
Computerized Maintenance Management System
CMMS Demo (System Description)
1
INTRODUCTION
What is Maintenance?
What are Maintenance Types?
What is CMMS?
What does CMMS Support?
What does CMMS Provide to Users?
2
CMMS DIAGRAMS
CMMS Block Diagram
CMMS Flow Chart
CMMS
INTRODUCTION
WHAT ARE MAINTENANCE TYPES?
Policies can be adopted by applying criticality assessment 1
Breakdown maintenance:
Run to failure,
Planned maintenance
Includes the following policies
• Preventive maintenance PM
Planned & Scheduled activities must be adhered
• Predictive maintenance PDM
Inspect, Report, Detect, Monitor & Correct
• Condition Based Monitoring CBM
Tool to forewarn impending or actual failures; interfaced to CMMS
CMMS
CRITICALITY ASSESSMENT:
Defining the risk of losses due asset failure; This covers the following Aspects:
1. HSE: health, Safety and environment
Compensations and penalties associated with:
Human injured or death
Facilities partial / total lose (Fire/explosion)
Environmental repair cost / governmental penalties (pollutions)
2. Production losses
Compensations and penalties associated with:
Fail to deliver product on contracted time
Fail to deliver product on contracted quality
Also; Production cost increases due losses of raw materials associated with failures
3. Cost of repair
Where critical component repair usually requires overseas vendors logistics
CMMS
Sample of criticality assessment
CMMS
WHAT IS CMMS?
C
CMMS stands for omputerized M M
aintenance S
anagement ystem.
It is a system – or a tool – that:
Uses computer technology to: Efficiently & effectively assist
The maintenance work management.
WHAT IS CMMS SOFTWARE?
CMMS software stands for Computerized Maintenance Solution.
It is an integrated software package used to manage the maintenance activities.
WHAT DOES CMMS MUST SUPPORT?
•Standard database as: (Oracle, SQL server or MS Access, etc.)
•Standard Operating Systems as: (Windows XP, Windows 7 and Windows 8, etc.)
•Multi users
•Multi language (English / Arabic, German etc.)
CMMS
WHAT DOES CMMS PROVIDE TO USERS?
Asset Register
Planning and Scheduling
Work Orders
Analysis and Advanced Options
CMMS
WHAT DOES CMMS PROVIDE TO USERS?
Asset Register
Flexible Equipment Coding
Ease of Equipment Location Identification
Availability of Equipment Technical Data (Specifications)
Accessibility of All Equipment-related Documents, Drawings and Videos
Ease of Recording Daily / Weekly readings
Ease of Defining Equipment Condition at any time
Ease of Getting all Historical Data for Equipment
Planning and Scheduling
Supports Different Maintenance types
Supports Different Maintenance Scheduling Types
(Calendar, Meter, Which is Nearest and Non-Routine Jobs)
Accessibility to Simulate, View, Modify and Approve Maintenance Plan
Resources Forecasting
Workload Distribution
CMMS
WHAT DOES CMMS PROVIDE TO USERS?
Work Orders
Accessibility to Issue Unplanned Work Orders (Work Requests)
Following up Work Orders Status throughout the Work Order Cycle
Analysis and Advanced Options
Accessibility to Group Output Reports; to Edit or Display Designed Reports
Equipment Performance Indicators
Spare Parts Consumption Analysis
Failure Analysis
Costing and Budgeting Analysis, and Maintenance Cost Control
Export / Import to spread sheets as: (Excel, louts) & project planning software a
(MS Project, Primavera)
CMMS
CMMS DIAGRAMS
Simple CMMS block diagram is introduced first, then
A detailed CMMS flow chart will be introduced next.
CMMS
CMMS BLOCK DIAGRAM
EQUIPMEN
TASK
T
EQUIPMENT/TASK
RELATION
WORK ORDERS
OUTPUT REPORTS
CMMS
CMMS BLOCK DIAGRAM
- Technical Details - Requires S/D?
- Spare Parts - Permits
EQUIPMEN - Work Scope
- Drawings TASK - Measurements
- Videos T
- Resources
EQUIPMENT/TASK RELATION - Measuring Points
UPDATE RESOURCES UNSCHEDULE
PLAN OVERVIEW
AUTOMATICALLY
WORK REQUESTS
APPROVAL
UPDATE STATUS NORMAL
WORK ORDERS APPROVAL
MANUAL
TUNE
PLAN
LY
EMERGENCY
W.O W.O W.O
PENDING FEEDBACK DELETION
W.O
- Failures Analysis HISTORY
- Cost Control
- Measurements
OUTPUT REPORTS
CMMS
CMMS FLOW CHART
CMMS controls plant maintenance through:
Locations & Tasks Resources
Equipment's
CMMS
CMMS FLOW CHART
CMMS controls plant maintenance through:
Locations &
Equipment's Resources
Man Power
Tools
Spars
Contracts and
Services
CMMS
CMMS FLOW CHART
CMMS controls plant maintenance through:
Locations & Resources
Equipment's
CMMS
CMMS FLOW CHART
CMMS controls plant maintenance through:
Resources
Locations & Equipment's
SITE SITE
(LOCATION) (LOCATION)
Each Site Contains
UNIT UNIT UNIT UNIT
(LOCATION) (LOCATION) (LOCATION) (LOCATION)
Each Unit Contains
SECTION
(LOCATION)
SECTION
(LOCATION)
SECTION
(LOCATION)
CMMS
CMMS FLOW CHART
CMMS controls plant maintenance through:
Resources
Locations &
Equipment's
GROUP OF SITES
(LOCATIONS)
Each Site Contains
Each LOCATION Contains GROUP OF
GROUP OF UNITS
EQUIPMENT'S
(LOCATIONS)
Each Unit Contains
Each LOCATION Contains
GROUP OF MECHANICAL ELECTRICA
SECTIONS Group of L
(LOCATIONS) Categories p of
Each Section Contains Categories
CMMS
INSTRUMEN HSE STATIC ETC..
T
CMMS FLOW CHART
CMMS controls plant maintenance through:
Locations & Resources
Equipment's
GROUP OF SITES Employees
(LOCATIONS) Tools
Spars
Each Site Contains
Contracts
GROUP OF UNITS
(LOCATIONS)
Each Unit Contains
GROUP OF
GROUP OF EQUIPMENT'S MECHANICAL ELECTRICA
SECTIONS Group of L
(LOCATIONS) Categories p of
Each Section Contains
Each LOCATION Contains Categories
CMMS
INSTRUMEN HSE STATIC ETC..
T
EQUIPMENTS
GROUP OF
Equipment Details MAIN / SUB (ROUTS) EQUIPMENT
EQUIPMENTS
Vendor
Manufacturer
Criticality
Type
Class A rout of equipment is used to group a number of real equipment together, such that
Log Sheet ONE task can be applied on ALL components of the rout tag at the SAME date in ONE
Technical Data (Specs) work order.
Materials/Equip Only one task/equipment relation will be available in the master maintenance plan.
Etc... System deals with the rout tag throughout the whole work order cycle.
rout Equipment concept is used to reduce number of issued work order.
CMMS
Tasks
Scheduled Maintenance
Unscheduled Maintenance
Master Plan
1. Relation (TASK - EQUIPMENT) OPTIONAL
Each relation contains one equipment to one task with the required (estimated)
(planned) resources defined
DRAFT
2. Base
EMERGENCY REQUESTS
Interval of the relation (Days, Meter Reading, or Next Due Date)
REQUESTS
3. Realize
Measurements as Vibration, Temperature, Thickness, etc…)
INITIAL APPROVAL
CMMS
From Planned From Unscheduled
APPROVED
REQUESTS
CREATE PLAN
OVERVIEW FINAL
Benefits of simulating the master
maintenance Plan: APPROVAL
Forecast actual plan
Prepare required resources Once it is approved, it is
Carry out an initial cost estimation ISSUE PLAN directly converted to issued
Approve plan (optional) or under execution
SHOW PLAN
Gives a chance for enhancements work orders (In progress)
OVERVIEW through: Manpower distribution,
Material Requirements, Required Issue W.O's for the
Budgets, Required Tools, etc… requested Period &
selected Equipment OPTIONAL
ISSUED WORK ORDERS
Once it is issued, it is
directly converted to issued
(optional) or under execution
work orders (In progress)
CMMS
ISSUED WORK
ORDERS
After removing
PENDING W.O pending reason
WORK IN
PROGRESS
WORK ORDERS
FEEDBACK
COMPLETED W.O
INITIAL APPROVAL
WORK ORDERS
UNDER REVIEW
FINAL APPROVAL
Registered history for each ARCHIVED W.O
Equipment In the plant
CMMS
WORK ORDERS
ARCHIVED W.O
FAILURE PERFORMANCE
ANALYSIS INDICATORS COSTING
Failed Components Reliability Cost Centers
Defects Utilization Assets
Causes Availability
Corrective Actions
Replaced Material Code
Component Manufacturer
CMMS
Thank You
CMMS
