Digitalization of plant equipment management to streamline maintenance and inspection operations.
A Computerized Maintenance Management System (CMMS) is a system designed to streamline equipment management in chemical plants and improve productivity. By implementing a CMMS, it becomes possible to centralize inspection histories, repair records, and parts inventory related to equipment maintenance management, as well as to formulate optimal maintenance plans based on historical data. This can lead to various benefits, including cost reduction in equipment maintenance management, improved work efficiency, and enhanced safety. The equipment management system "Maintenance Station" is a CMMS that is simply structured with only the necessary functions, based on a wealth of experience in supporting equipment maintenance management in the industrial sector. The digitalization of equipment management enables the sharing of equipment management data, the efficiency of equipment management operations, and the reduction of maintenance costs. *CMMS: Computerized Maintenance Management System
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basic information
■ What is the Equipment Maintenance Management System "Maintenance Station"? Utilizing various data such as equipment information, work information, and failure information, it optimizes operations by establishing better work plans regarding what, when, and how maintenance should be performed. ■ Function List [Equipment Management] - Manages the hierarchical structure of equipment, attribute data, and part information linked to the equipment. [Inspection Management] - Registers and manages input items for maintenance tasks (regular inspections, preventive work, etc.) related to equipment. - Supports remote work on-site using tablet devices (offline input is also possible). [Failure Management] - Issues work instructions for failure response when unexpected failures occur. - Accumulates work instructions by equipment unit, allowing reference to failure history for each piece of equipment. - Supports past trouble investigations by classifying failure responses into "phenomenon - cause - factor - action." [Cost Management] - Aggregates the costs (time and money) of maintenance work by equipment unit. [Inventory Management] - Manages replacement parts for equipment (replacement cycle, last replacement date, etc.). - Manages parts at the warehouse level and oversees the inventory status of replacement parts. [Aggregation and Analysis] - Supports data output in accordance with existing standard report formats. - Assists in the creation of reports for data analysis.
Applications/Examples of results
- Case Study: Condition Monitoring Maintenance through Equipment Information Visualization A case of standardizing maintenance operations for production equipment and visualizing equipment status. Before 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 high labor costs for maintenance operations. By introducing a maintenance management system, standardization of maintenance operations for production equipment was achieved, enabling automation and efficiency improvements in maintenance tasks, as well as condition monitoring maintenance through the visualization of equipment information. - Case Study: Visualization of Parts Inventory A case of visualizing parts inventory through a maintenance management system at a chemical plant. The company experienced equipment downtime due to a shortage of parts inventory during equipment repairs, which halted operations until the equipment was restored. To align the equipment inspection plan with actual failures, a maintenance management system was implemented, achieving visibility of the inventory of repair parts. This resolved the parts inventory shortage and significantly reduced the impact of breakdowns on planning and production.
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Maintenance Management System (Maintenance Station)
Current Status and Challenges of DX in Manufacturing Management in the Chemical Industry
Case Study: Standardization of Maintenance Operations for Production Equipment and Visualization of Equipment Condition
Case Study: Improving Productivity of Maintenance Operations through Paperless Maintenance and Inspection Tasks
Case Study: Visualization of Parts Inventory
Current Status and Challenges of Aging Equipment Countermeasures in Chemical Industry Production Facilities
Current Status and Challenges of Aging Equipment Countermeasures in Food Factories
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