Case Study: Standardization of Maintenance Operations for Production Equipment and Visualization of Equipment Condition
Automated the extraction and planning of maintenance work for production equipment, reducing the annual maintenance planning workload by approximately 90%.
■About the Maintenance Management System (Maintenance Station) An equipment management solution that integrates and optimizes facilities and operations. By utilizing data such as equipment information, work information, and failure information, it helps to create better work plans by determining what, when, and how maintenance should be performed, thereby optimizing operations. It improves operational efficiency and safety, reduces costs, extends the lifespan of equipment, and provides a "safe and secure" environment.
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basic information
Standardization of maintenance operations for production equipment and examples of equipment condition visualization. Prior to implementation, there were discrepancies in maintenance ledgers and work procedures at each site, and tasks such as visual checks, double entries, and searches took a lot of time, resulting in a significant amount of labor for each maintenance operation. By introducing a maintenance management system, we achieved standardization of maintenance operations for production equipment, enabling automation and efficiency of maintenance tasks, as well as condition monitoring maintenance through the visualization of equipment information.
Applications/Examples of results
[Challenges Before Implementation] - It takes time to create and search maintenance plans. - Double entry of work details. - Visual checks for maintenance work performance management. - High labor hours for collecting and aggregating actual data. - No equipment records for investigating equipment factors. [Effects of Implementation] Achieved automation and efficiency in maintenance operations through standardization of documented content, visualization of inspection history, and automatic creation of diagrams. - Labor hours for creating maintenance plans: Approximately 90% reduction. - Labor hours for inspection/actual input: Approximately 50% reduction. - Labor hours for extracting unperformed items: Approximately 66% reduction. - Labor hours for automatic creation of equipment records: 75% reduction, among others.
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Case Study: Standardization of Maintenance Operations for Production Equipment and Visualization of Equipment Condition
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Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools
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