System introduction

The maintenance system, despite being a new science, is one of the most important parts of organizations and companies. The reason is the significant role of this sector in increasing the financial and productive efficiency of the organization. What is defined today as a maintenance system is a set of activities to identify, predict and prevent failure and prevent equipment and effective facilities in production, with an economic approach.

Perhaps the most important issue in today's world is the production of quality and economic products, in which production equipment is one of the most important parts. Production equipment over time faces issues such as depreciation, gradual and sudden stresses, power outages and overuse of the machine or reduced equipment efficiency. These issues reduce efficiency and consequently reduce the quantity and quality of products and consequently produce more defective products, increase semi-finished products and ultimately increase the cost of products.

The important point here is the gradual and intangible increase in costs. As equipment repair costs are not typically considered separately in the financial statements, the necessary financial reports are not available. Another concern is that many of the costs of equipment breakdowns covertly reduce productivity. For example, sleeping on a piece of equipment in a work shift, in addition to the cost of repairing the equipment, will cause a lot of losses due to production delays, labor costs, the possibility of producing waste, the cost of customer dissatisfaction with product delivery delays and many other such costs. , Enters.

Recognizing the need for timely maintenance and repairs led to the production of many methods to realize the idea ("prevention is better than cure"). At the same time, more inspections, more parts replacement, more parts costs and also higher repair costs to organizations And imposed industrial companies. This was also carefully researched by global experts and led to the invention of methods by which the optimal economic point of view of the volume of maintenance activities can be found.

Mechanized System using Advantages

- Preventation of the development of defects  and eliminate even the minor of it, before the need for overhaul
- Maximum prevention of interruption in production operations by replacing worn parts before breakage and disabling the machine
- Reduction of production stops due to emergency repairs, supply of spare parts and prevention of losses due to work interruptions
- Saving manpower due to the reduction of repair operations
- Reduction of general and repetitive repairs as well as reduction in the consumption of spare parts and reduction of related costs
- Reducing the volume of substandard product and increasing the quality of products - Increasing the life of machines and saving on buying new machines

System Features 

- Definition of equipment ID
Defining the information of the organization's machines to perform maintenance and repair work on them, including: location, class, production line, machine tree, etc.

- Define work calendar
Determining machine working hours and defining different and unlimited calendars for work units and equipment for use in preventive maintenance planning and OEE reporting

- Scheduled maintenance and repairs
Definition of preventive maintenance (PM) and condition monitoring (CBM) equipment equipment based on various schedules according to the work process of the organization and the requirements of each device, planning, recording reports related to the repairman, measures and consumables

- Unplanned maintenance
Registration of repair requests (emergency (BM), correction (CM), carpentry), expert review, referral to the relevant repairmen and finally registration of reports related to the repairman, actions and consumables

- The actual operation of the equipment
Defining the standard production time of the product per machine, recording the daily operation of the device based on (hours, impact, kilometers and parts), recording the amount of production (healthy, defective) and recording the successes (planned and unplanned) of the device