設備維護應用系統整理

設備維護應用系統整理Fred Wang(http://fredwang.blogspot.com)

Feb,2005
下面是一些設備維護管理應用系統的觀念整理, 及SAP相關的應用模組等的整理筆記。

設備維護系統的發展
企業由於資源，成本等限制而在設備維護系統有不同的發展階段，如下:
1. 出錯再修
2. 有效的手動管理系統
3. 標準化維修流程，程序與政策
4. 電腦化維修管理系統(CMMS, Computerized Maintenance Management System)
5. 整合性物料與採購系統
6. ISO9000認證
7. 可靠度中心的維護(RCM, Reliability Centered Maintenance)
8. 95%設備效率
9. 企業資產管理 (EAM, Enterprise Asset Management)

維護管理的思想
下面是幾個主要的維護管理階段的目標
CMMS :
1. 定義管理規則，組織與職責
2. 運用工具進行標準化管理
3. 在組織間進行訊息分享
ＲＣＭ
1. 提高企業營運的可靠度
2. 減低維護工作量與成本
3. 延長設備使用壽命
ＥＡＭ
1. 定義所有需要維護的資產
2. 維護所有需要維護的資產
3. 管理所有需要維護的資產

SAP Solutions for EAM
ＳＡＰ在ＥＡＭ應用的相關模組:
 -Core SAP PM, MM, PS, QM
 -SAP Business Intelligence for EAM(SAP BW, SEM)
 -Portals for EAM

CMMS應包含之功能
 工作管理
1.日常工作最佳化 (物料, 工具, 人力等)
2.檢修工作管理 (檢查重複性工作)
3.支援預防保養計劃
4.處理緊急維護工作能力
 實際的資產管理 (Physical Asset Management)
1.CMMS資料歸檔管理能力
2.快速且容易取得重要資訊(包括計劃/非計劃工作歷史,資產統計資料,保固和服務合約,數位化文件包含 CAD 繪圖,等等)
 資源管理 (Resource Management)
• 支援完整庫存控制
• 支援完整採購系統
• 追蹤內部和外部人力成本
• 服務契約成本
• 整合工時管理程序和財會套裝軟體將使管理系統達到最佳化

What is RCM?
 Methodology used to identify undesired equipment failure consequences
 Develops a cost-effective PM strategy to prevent those failures
 Continuous to improve reliability over life of plant
 Shift PM program away from time-based and towards condition-based activities

What is APM?
 Leverages critical asset performance data from enterprise and local sources (ERP, CMMS, DCS, and other discrete systems),
 Publishes key performance indicators (KPIs) enabling identification of improvement opportunities,
 Automates technical data analysis to identify and predict failure occurrence and cause,
 Supports continuous improvement of operational, surveillance, maintenance and design strategies based upon best practices, operational history and fact-based decision support,
 Drives strategies back to execution systems to close the loop and continuously improve asset performance across the enterprise.


The Business Solutions
 Use state of the art Reliability Analysis (RCM) system with your SAP PM system
 Configure SAP to capture the data for Reliability
• Functional Location, Equipment Classification, Catalog Profiles, etc…
 Configure RCM system to mirror the SAP data structures
 Interface SAP to RCM to push the data


Appendix . APM & RCM Example
Meridium Enterprise Reliability Management System
 Software Functionality
• Reliability Analysis
• Risk-based Inspection
• KPI and Metrics
• Instrument and Calibration Management
• Asset Strategies
• Root Cause Analysis
• Inspection Optimization
• RCM


Reference
 -Typical Lean Manufacturing (TPM) Process Flow”, Life Cycle Engineering Inc.
 -Larry Johnson, “Populating MAXIMO with RCM results”, FractalSolutions.com
 -Meridium Software Functionality
• http://www.meridium.com/software/functionality/index.asp?bhcp=1
 -Vince Flynn, “Using SAP PM for Reliability Analysis”, E. I. DuPont deNemours & Co. Inc.
 -“設備維護管理的發展與趨勢”
• From :www.cesh.itri.org.tw/tech/cmms/equip.php
 -SAP R/3 Interface Advisor
• http://service.sap.com/int-adviser