Lean equipment management system

Overview

With persistent information construction of manufacturing, large manufacturing enterprises have initially established enterprise management information system with the core of enterprise energy plan(ERP) system and improved enterprise’s management level; meanwhile, it also puts forward higher requirement for information work. In order to actually guarantee product quality and equipment operation maintenance cost to improve the real-time and flexibility of the plan, also to improve the operation efficiency of production line improvement, as the basis of plant operation, how to effectively conduct equipment management has become the core problem that all enterprises care.

Product characteristics

Through many years of manufacturing industry accumulation, Chinasoft International has dominated the leading role in the field of equipment management. It has constructed equipment management project implementation for many manufacturing enterprises by the “shelf” based IT application structure and ESB bus technology adopted to comprehensively integrate the equipment data resources of corporate company and plant department, optimize and improve equipment management system and fulfill six elements of equipment management business, namely: management planning, equipment prophase management, equipment post management, management evaluation, continuous improvement and equipment basic management, to support group unified management and control with the whole life cycle of supporting equipment as the core; realize “data integration, resource integration, information sharing and intelligent smart decision making” by the establishment of comprehensive data acquisition, data analysis model and prediction system to support business management demands of corporate company and plant departments in all directions, multiple dimensions and multiple methods, and construct a business platform covering equipment management within the group. Through the data delivery of site terminal and mobile terminal, make the equipment management actually extend to the field side of the equipment, realize the management mode of "finding people for things", provide data management and decision-making support services for personnel at all levels, improve the work execution ability, and improve the equipment management and control level of the enterprise.

The lean equipment management system of Chinasoft International contains following content:

1. Management target planning

Attach importance to process control based on equipment management and prevent risks in daily management to facilitate following management evaluation and testing of each department, including group level target management, plant level target management, workshop level target management and equipment management target process management, etc.

2. Equipment prophase management

Realize the reasonable layout of productivity around the future development strategy and planning requirements of the group company, it is the whole process management from planning, selection and procurement to equipment arrival acceptance and installation and commissioning, including: equipment planning and selection, procurement link visualization, equipment arrival acceptance, equipment installation and commissioning, etc.

3. Equipment anaphasemanagement

Equipment anaphasemanagement is also the daily operation maintenance management of the equipment, it mainly makes the equipment to keep in good work condition to complete production tasks. The typical characteristics of the overall process of the system is to realize prevention and maintenance close loop, hidden issue close loop, failure maintenance close loop and spare part management close loop, including equipment standard management, self-maintenance management, equipment spot check management, professional maintenance management, equipment lubrication management, on-line equipment status monitor, hidden issue management, equipment repair management, equipment shutdown management, equipment failure intelligent diagnosis, equipment inspection issue, spare products and parts management, equipment technical renovation management, equipment accident management, personal work station and etc.

4. Equipment management evaluation

Equipment management evaluation is to realize the classification and definition of evaluation index by establishing equipment evaluation index base, establish analysis model, statistic and analysis and performance and evaluation of evaluation performance index, so as to realized equipment management and analysis in the whole period.

5. Equipment continuous improvement

Equipment continuous improvement is to conduct regulatory management and tracking of all kinds of improvement activities and proposals in the equipment management process through the establishment and management of equipment knowledge base, and achieve the final target of continuous knowledge innovation through obtainment, creation, sharing, integration, record, access, update, comment, analysis, refinement and other process. It mainly includes lean improvement management, equipment knowledge base management, training management and etc.

6. Equipment basic management

The main purpose of equipment basic management is to construct equipment basic model and support the operation of the whole equipment management system. Equipment basic model mainly includes: equipment basic data, equipment BOM, equipment file management and other parts. Equipment basic data defines the basic code information, business realization rules and standards required by equipment management; the equipment takes the master data assigned by ERP including model, position, part, production line, process section, rated capability ,actual capability, ABC classification, working age, asset code and other equipment information as the basis, and takes the equipment model as the grasp to realize equipment tree structure including model information, position information, part information and spare products and spare parts information, which is equipment model BOM; record the resume information and data information of each kind of equipment in the equipment file to realize the tracing and query of the whole life cycle of the equipment.

7. Mobile internet management

Mobile internet equipment management is divided into mobile site business processing platform and mobile information query, these two parts are not completely independent, but mutually cooperative to jointly realize mobile requirements of equipment management by corporate company and plant, as well as to realize the highly efficient management model of rapid identification of target subject, rapid positioning of work content, rapid delivery of information data and rapid analysis of result record, support the plant equipment management level step to lean equipment management through problem finding, all staff improvement, service evaluation and experience exchange. The main functions of mobile site business processing platform are equipment spot check, equipment lubrication, equipment maintenance, equipment repair, call for repair and site shift; the main function of mobile information query platform include mobile electronic bulletin, equipment responsible person information query, equipment static and dynamic information query and display, etc.

8. Data application analysis

Data application analysis is divided into two-level management function of group and plant, the respective content of their data application and analysis is as follows:

Group-level data application function

Equipment overview: equipment quantity layout, equipment original value layout, equipment working age layout

Equipment operation analysis: equipment comprehensive efficiency, equipment utilization

Maintenance cost analysis: comprehensive maintenance cost and proportion of maintenance cost

Spare parts inventory analysis: inventory amount of spare parts, capital turnover rate of spare parts

Equipment and production analysis: to conduct comparative analysis from two dimensions – equipment and production plan

Equipment and quality analysis: to conduct comparative analysis from two dimensions – equipment and quality

Equipment and material analysis: to conduct comparative analysis from two dimensions – equipment and material

Equipment and consumption analysis: to conduct comparative analysis from two dimensions – equipment and consumption

Plant-level data application function

Equipment overview: equipment quantity layout, equipment original value layout, equipment working age layout

Equipment operation analysis: equipment comprehensive efficiency, equipment utilization, equipment failure analysis

Work management analysis: construction of all kinds of repair modes, on-time completion rate of maintenance plan, fault tree reference rate

Maintenance cost analysis: comprehensive maintenance cost, proportion of maintenance cost, equipment energy consumption analysis

Spare parts inventory analysis: inventory amount of spare parts, capital turnover rate of spare parts

Service advantages

Resource advantages

It possesses the high-end resource integration of CIMS center of Tsinghua University, implementation team with rich experience, fully supported staff size and aggregation capacity of socialized high-end resources

Mature product
Through comprehensive productization, the lean equipment management system of Chinasoft International has been verified by many large enterprise projects.