COMPUTERS

IN
MAINTENANCE
Introduction
 Systematic maintenance planning ---
temporary stoppages and shutdowns
 Online monitoring --- performance is
checked at regular intervals.
 FMS --- change of a broken tool is
automatically done with the help of
program provided in the computer system.
 Artificial intelligence --- operations
performed by the robots.
Computer Maintenance
System
 Development of a database.
 Analysis of past records if available.
 Development of maintenance
schedules.
 Availability of maintenance materials.
 Feedback control system.
 Project management.
Job Card System
 To record the maintenance work
carried out or the work to be done.
 Plant code.
 Equipment code.
 Job code.
 Nature of the jobs.
 Time of initialization of the card.
 Start time of the job.
 Finish time of the job.
 Man hours spent and so forth.
 Job Card Procedure
 Job list received from control office or job planning office
 Job cards are prepared and issued for every activity.
 Job cards placed in loading board/rack against names of men
allocated or supervisor for preventive maintenance and other
jobs.
 Completed job cards checked by issuing supervisor.
 Notes made for corrective works required and fresh jobs issued
and placed in the loading board/rack.
 Job list signed and summary of manpower completed.
Inventory Control

 Maintenance work always suffers due to

non-availability of spare parts.

 Forecasting spare parts and other

relevant matters can be improved by
the use of computers.
Inventory Control

 What Is It???
 Inventory control means keeping track of
your stock
 Knowing how much was sold and how much
is left
 Let’s you know when to order more fuel
 Let’s you keep records of losses and gains
 Gives you consumption rates of high demand
and low demand
Inventory Control

 HOW DO I KEEP INVENTORY???

 By using inventory data sheets
 Daily Readings
 Daily inventory balance record
 Monthly Summary
 Regular tank dipping
 Regular meter reading
Daily Readings Product

Month Year

Pump 1 Pump 2 Pump 3 Pump 4 Total Tank 1 Tank 2 Total

Meter Dip Inventroy Water Dip Dip Inventroy Water Dip Physical
Day

Readings Sales Readings Sales Readings Sales Readings Sales Sales cm. litres cm. cm. litres cm. Inventory
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7 This is were information collected from meter
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totals and tank dips are added and recorded.
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Daily Inventory Balance Record Product

Month Year

1 2 3 4 5 6 7
Day

Opening Physical Deliveries Meter Sales Inventory Should Be Physical Inventory Variation Today Variation This
Inventory Month
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2
3
4
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6
Balance sheet is were information is calculated to
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determine losses and gains from daily sales. This is a
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very important part of fuel management it will give
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you important records of sales (this is inventory
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14 control).
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TOTALS
 Monthly Summary

Product Product Product

Storage Capacity Storage Capacity Storage Capacity
Total Variation Total Variation Total Variation
% Loss % Loss % Loss
Month Sales for Month Sales for Month Sales for Month

This is were we record our calculated losses and

gains for every individual month. This sheet is
used for the years sales report. Will give you
sales of individual months. Record keeping is a
important method of tracking your inventory.
Maintenance Material
Planning
 It is possible to know the precise
material requirements in advance and
therefore the procurement process of
quality products can be initiated well in
time.
Feedback system

 The reports from the computer program

can be matched with the actual jobs to
find out any deficiency.
Use Of Network Methods

 Detailed networks showing the time for

each activity can be drawn up in
consultation with the maintenance
personnel.

 The completion time of each

maintenance job can be easily
calculated to help planners to make the
maintenance schedules.
Maintenance Cost System

 The month-wise details of cost of

maintenance in respect of each plant
can be prepared indicating labor cost,
material cost and overhead
expenditure.

 The actual cost is then compared with

the budgeted cost.
Spare Parts Life
Monitoring System
 Spares repeatability in various
machines indicating the performance of
such spare parts.

 Comparisons of the actual life with the

estimated life of the spare parts.
Spare Parts Tracking
System
The total time required to rectify a
breakdown of a machine is the sum
total of the times required for each of
the following operations.

 Time to identify the cause of the failure.

 Time to determine the requirement of spare
parts.
 Time to procure the spare parts.
 Time to rectify the failure.
 Reports that can be maintained by the
use of computers,
 A complete list of breakdowns with reasons, for
all equipment, on a weekly/monthly/yearly
basis.
 Repetitive kinds of breakdown, indicating the
frequency of failures.
 Mean time between failures and the expected
repair time, equipment wise.
 Spare parts repeatability in various machines
with their performance in each machine.
 New spare parts life monitoring.
Maintenance Information
System
 Decision making information
 Identify problems
 Develop solutions
 Take corrective actions
 Control the actions
 Measure the performance
 Administrative information
 Route data reports
 Open work order listings
 Preventive maintenance inspections
 The Information In Respect Of
Maintenance Functions Can Be
Collected At Various Levels
 Unit Level
 Required items of information are listed out for computerization.
 Information about breakdowns must be collected.
 Idle time costs of equipment.
 Material cost.
 Labor cost.
 Aggregate Level
 Compilation of information.
 Information collected is presented in the form of
monthly/quarterly/annual reports.
Computer Simulation In
Maintenance
 Forecasting can be done with the help of a
computer using real life data, knowing the
pattern of failures (ie. Distribution) the desired
data can be simulated.

So breakdown and repair time data of each

component of an equipment need to be carefully
analyzed for establishing the following
 Breakdown distribution
 Breakdown period
 Distribution of length of the time.
Maintenance Decision
Making
 TPS (Transactions Processing Systems) have looked at records of
components, spare parts, fixtures and tools as inputs and
consumption statements and maintenance accounts as outputs.
Other information:

 Equipment conditions
 History of failure
 Direct cost of maintenance
 Inventory values and material movements
 Man-hours spent on maintenance
 Overtime paid, usage of other facilities made
 Performance of the maintenance workforce
 Reliability and maintainability of equipment and maintenance cost
per unit of production.
 From these database, maintenance reports can be generated for equipment control, work, control, craft
performance, maintenance performance, over time, delay in work.
Expert Systems

 These are the computer programs built

for commercial applications using the
programming techniques of artificial
intelligence, especially those techniques
developed for problem- solving.

 Medical diagnostics.
 Electronic fault finding.
 Mineral prospecting.
 Condition monitoring.