Features

Automatically identifies

Downtimes allows a correct assignment of times to the events that produce the stoppages within your plant. Automatically identifies the asset of the event (crushers, mills, belts, giant equipment, light fleet, among others) and the area to which it belongs: Operations, Maintenance, Mine, 'Stand by', (customizable by the user) or both in order to make an adequate calculation of the Maintenance KPIs.

Asset and Area

Automatic detection of stoppages in critical assets (crushers, mills, belts, giant equipment, light fleet, among others) and constant monitoring of key maintenance indicators such as Physical Availability, Mechanical Availability, Utilization, Mean Time to Repair (MTTR), Mean Time Between Failures (MTBF), Top Ten Failures, among others.

Data Analysis

Integration and historicization of condition information, general display of asset status, general detail display by specific equipment, categorization of assets by area. The analysis of the data obtained through instrumentation or with help to identify which components of the equipment or machinery need to undergo revision or maintenance, thus optimizing the inspection process, which can be carried out with a real-time display of maintenance indicators, managing the reports.

Records

It helps to carry out the analysis of the root cause of the failures, the responsible area and the maintenance workshop with the highest number of arrests, to establish action plans that help reduce downtime of critical equipment, reducing maintenance costs and increase the availability of critical equipment. Therefore, the user can register maintenance schedules, budget and forecast information in order to visualize in real time the comparisons and/or deviations between what is planned vs. real.

Workflow - Event Module

1. Automatic Detection Capture

Specification analysis for the generation of arrests according to the behavior of the equipment. Event Frames generation in AVEVA PI System, with times detected in millisecond. History of Detentions according to the Line, by equipment and by Responsible Area.

2. Detentions Display

Interface to visualize the detentions occurred in a certain time (Shift, Day, Week). Historical Search of Events already registered. Personalized Search of Detentions according to the day, the affected line, the type and status of the event. Export of searches in different text formats.

3. Specific Assignment

Exact assignment of time to the different areas of the organization (Maintenance, Operations and Unscheduled Time). Maintenance Times Branch based on the workshop that intervened. Wide judgement when cataloging arrests (Type of intervention, Failure Modes, Workshops, Type of Equipment, System and Affected component). Correct assignment of dead times (invalid detentions) not affecting the calculation of KPIs

4. Registry of Budgets, Forecasts and Action Plans

Budget registration by equipment, line and plant (monthly and annual). Forecast record by equipment, line and plant (weekly, monthly and annual). Definition of action plans based on the performance of the equipments and their criticality. Personalized record of maintenance calendars.

5. Automatic Reportability

Calculation of indicators in real time, week to Day (WTD), Month to Day (MTD) and Year to Day (YTD). Analysis for the reliability and criticality of a equipment, line or plant. Availability and Effective Use Chart. MTBF and MTTR graphics. Jack Knife graphics. Pareto Graph of Equipment by Frequency and Time by Lines, equipment, system and component. Top Ten Trend Monthly Failure Frequency by Equipment, System and Component. And more.

Workflow - Monitoring Module

1. Logic Configuration Connected

It allows to connect, collect and store the information of variables in operations coming from the control systems. Collection that can come from other data sources such as vibration analysis. In addition to manual inputs such as oil and wear analysis results.

2. Condition Logic Configuration

Interface to visualize the detentions occurred in a certain time (Shift, Day, Week). Historical Search of Events already registered. Personalized Search of Detentions according to the day, the affected line, the type and status of the event. Export of searches in different text formats.

3. Execution of Conditions Logic and Visualization

This execution is carried out in real time and is updated in the monitoring Dashboards. Alert and notification settings. It allows to visualize in real time through the monitoring portal the general status of the equipment according to the configured conditions.

Upgrade Timeline

  1. Web application.

    Time allocation by responsible area.

    Equipment record – System – Component.

    Failure modes 1 and 2.

  2. Creation of Sub-events on two levels.

    Mass filling of events.

    Registration of Budgets and Forecast.

    Dashboard of Indicators.

  3. Registration of Maintenance Schedules

    Record of Action Plans.

    Creating Manual Stops.

  4. New Dashboards: Top Ten Teams, Top Ten Failures, Arrest Pareto, Availability Weekly-Monthly-Yearly, MTBF and MTTR, Plant Maintenance and Jacknife diagram.

    In-house File Management Engine (PIPER).

  5. Security Module.

    Administration Module.

    Email sending Module.

    Saving of Times by areas for the calculation of indicators.

  6. Notifications module.

    Data concurrency.

    Advanced filters.

  7. Dynamic division.

    Multiple templates.

    Authorization module.

    Log system.

  8. Own administration and configuration module, detention storage database and indicator creation and configuration engine.

    Reliability module.

    Predictability module.

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