Asset Optimization

Solutions

Asset Optimization Solutions

Will Help to identify and Improve

the true Potential of

existing Plant and Machinery

MESManufacturing Execution System

• Not getting the desired output from every Production assets due

to unplanned Downtime

• Discrepancy in Design v/s Actual output from Production assets

• Cannot realize full ROI on Investments made in Production assets

• Data collected on the Shop floor not helping on proper Analysis to

apply improvement measures

• Unexplainable Delivery failures due to lack of authentic data

• Availability, Rejection & Productivity not being appropriately

measured so as to arrive at daily OEE across the plant

• Figures such as OLE and OPE not available due to lack of correct data

• Not able to apply TPM principles to help in CIP (Continuous

Improvement Programs) to optimize on Asset Utilization for Production

Business Concerns related to Production

ERP

MESField

Controls

The MES Overview

` `

MES System

Machine StoppageData Options

Data File Counter

Data File HMI P.B. Panel

Production Data Options

PLC in case of H/W Interfaces

OR OR OR

System Architecture

The MES Solution

•A comprehensive Production MIS covering various reports

required for standardization of information outputs

•An Integrated System to help in reducing Data

Redundancy and provide Authentic data from the system

on a regular basis

•Data can be captured either manually or through

electronic interfaces with the Machines, if possible

•A Scalable application considering the future growth of

the Organization making it compatible to TPM ideology

The MES Solution

•Will help to save on…

- Time to analyze the daily production data.

- Time to analyze the daily Rejection data

- Time to analyze the daily Production Lost time Data

•And will also provide OEE, OLE and OPE figures

•Will help to reduce the response time in analyzing the data

and thus lead management in taking timely action wherever

required

•Offers data Security at multiple levels of Management

•Standardize the reporting system for all the Sections and

Machines throughout the organization

The MES Solution

•Store Production Data in a Database Server instead of

discrete files to minimize the risk of Data loss

•Objective based Implementation will help to successfully

deploy the system in your Organization

•Is closely integrated with our existing FTM System as part of

your daily workflow

MES is fast to Deploy & Easy to use !!!

Asset Maintenance

• Productivity being directly hampered because of Breakdowns

• Repetitive problems decreasing the overall efficiency of Machines

• A lot of time being spent by Maintenance before Audits due to lack of

proper records being maintained

• Lack of proper Spares Management increasing cost of Maintenance

• Non-compliance to Preventive Maintenance schedules

• Not able to correctly quantify planned v/s unplanned maintenance jobs

• Doubts in Reliability of all Corrective Maintenance jobs

• Not realizing the full potential of TPM philosophy – Kaizens, Jishu Hozen,

5S, etc. not being implemented practically on a long term basis

• Not able to set Performance Measurement Benchmarks and targets to

improve upon Maintenance operations

• Maintenance being demoralized due to criticism by everyone in spite of

extra hours being spent in the plant

Business Concerns related to Maintenance

Prodn. Divn. 3

Factory

Prodn. Divn. 1

Prodn. Divn. 2

Section 1 Section 2

Machine 1 Machine 2

Attached Documents

4 Level Machine Breakup

Specific Spares

Instruments & Gauges

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

Jobs Affecting

Production

Jobs Not Affecting

Production

&Work

ManagementThe

Factory

Work Management

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

&

Man Power Spares

Internal External

ConsumableRecyclable

OrRepairable

The Fault Tree

Fault Nature

Fault Code

Cause

Cause 1

Cause 2

Resource Management

The FTM Solution focuses on …

•Improving Production Uptime - By monitoring % Breakdown,

MTBF & MTTR

•Plant Health & Operating Costs

•Machine-wise Maintenance Cost - By getting Spares and

Manpower cost

•Effective Spares Management

•Effective Repairs Management – Track the Recycling of Spares

•Root Cause Failure Analysis by eliminating

repetitive failures

The FTM Solution focuses on …

•Developing a Centralized Knowledge Base

•Streamlining the Workflow & Quantifying your Work

•Improving PM, Proactive Jobs & Condition Monitoring

•Optimum Utilization of Resources

•Effective & Timely Documentation

•Realizing Total Plant Reliability

The FTM Helps to Achieve

RCM - Reliability Centered Maintenance

CBM - Condition Based Maintenance

TBM - Time Based Maintenance

RCFA - Root Cause Failure Analysis

CIP - Continuous Improvement Processes

FTM is fast to Deploy & Easy to use !!!

Contact Information

Werardt Systemss Pvt LtdPune, India

Phone : 91-20-25285256, 25285257

Website : http://www.werardt.com

email: business@werardt.com