Integrated Maintenance Planning as an Alternative to Outdated Software Models
Many companies are currently facing the same scenario: their current software is no longer supported, and the software provider is offering a migration to the cloud that is not exactly cheap. What are some ways to deal with this? In the chemical industry, combining inventory management and maintenance planning in a single software solution offers a strategic alternative. This integration not only solves the problem of outdated systems, but also optimises safety checks, maintenance processes and the management of protective equipment.
A holistic view of operational safety requires continuous monitoring of work equipment, inventory, employee qualifications and warehousing. Separate software products or mixed analogue-digital management structures create friction losses at the interfaces. A consolidated solution eliminates these inefficiencies. Inspections and timely maintenance measures ensure trouble-free operation – a decisive factor for safety and productivity in chemical production plants.
Structured recording through systematic categorisation
The uniform digital recording of a wide variety of operating resources plus integrated maintenance planning places special demands on the system architecture. Installed machines and systems, transportable tools, industrial trucks and infrastructure components such as heating and lighting systems require flexible categorisation.
A proven approach structures operating resources into hierarchically organised top-level categories with defined properties. A top-level category such as ‘Machines’ includes technical details, location information and responsibilities, for example. Subordinate categories differentiate between production or logistics areas. Through systematic inheritance, subordinate objects inherit the properties of their parent elements.
Maintenance activities are stored flexibly as defined actions at different hierarchy levels. Daily visual inspections may apply to all machines, while electrical inspections in accordance with DGUV V3 only affect specific systems at specified intervals. The system automatically assigns the necessary maintenance and inspection dates as soon as a piece of equipment is assigned to a category.
The formation of networks enables the logical grouping of related systems. Work equipment can be linked according to spatial criteria in production sections or according to functional dependencies. Maintenance planning thus highlights scheduling conflicts and enables the coordination of maintenance work to minimise production interruptions.
Cloud Systems and Intelligent Sensors: Technological Integration
Cloud-based systems ensure the location-independent availability of centrally managed data. Web applications enable access from various end devices, including smartphones and tablets. Employees can work flexibly with the system without having to open the company network. Independent availability via secure cloud servers increases flexibility while ensuring data security.
The integration of intelligent sensors significantly expands the possibilities for automation.
Maintenance intervals do not depend exclusively on fixed schedules. Networked sensors continuously record relevant parameters: GPS trackers locate mobile work equipment, temperature and humidity sensors monitor environmental conditions, and distance sensors measure signs of wear and tear. The battery-powered devices communicate with the inventory system via special radio protocols such as LoRaWAN (Long Range Wide Area Network).
Digital document management completes the integrated system. Forms are filled out digitally, and images and scans are integrated directly. Each piece of equipment has a complete digital history of maintenance measures carried out. The immediate availability of all documents simplifies control processes and eliminates the need for physical archives. Employees digitally check the proper condition of work equipment at the start of work. All necessary documentation is immediately available for inspections.
The integration of personnel information completes the holistic approach. Digital personnel files in protected system areas document qualifications, training and certifications.
The system automatically checks employees’ authorisation for specific work equipment. The integrated training planner manages dates for training and further education. Internal instructions and safety instructions are systematically organised and documented. This comprehensive view of people, machines and processes forms the foundation of an effective compliance strategy in the chemical industry.
Source: Trade journal ‘Chemie Technik’
Photo: Zamrznuti tonovi
