Summary of Computerized Maintenance Management Software (CMMS) Overview
CMMS Overview: Computerized Maintenance Management Software Explained
Introduction
This study guide covers practical steps to implement a structured maintenance plan and the influence of modern technologies (IoT, AI, Big Data, immersive applications) on maintenance and quality. The focus is on designing processes, organizing data, and applying modern tools to shift maintenance from reactive to proactive and predictive approaches.
Definition: A maintenance plan is a predefined set of activities, schedules, and resources designed to keep equipment and assets functioning safely and efficiently.
Part 1 — Building the Maintenance Plan (from zero)
Start with a complete inventory and build structured data and processes around it. A good plan is designed by maintenance staff and then managed by software tools.
1. Inventory and Registration
- Create a full inventory of equipment and assets to be maintained. Include location, model, serial numbers, criticality, and operating parameters.
- Assign a consistent coding scheme for equipment and assets to enable filtering and reporting.
Definition: Asset coding is a systematic identifier assigned to each asset so it can be tracked and referenced in maintenance records.
Practical example: For a plant with pumps and motors, use codes like PUMP-01-MTR-100 for Pump 1 motor; include installation date and expected life.
2. Personnel Records
- Register all maintenance personnel with specialties, certifications, contact data, and training history.
- Map technicians to tasks by skill level (e.g., electrical, mechanical, instrumentation).
Practical example: Store technician certifications and link them to tasks that require certification before assigning a work order.
3. Task and Parts Catalogs
- Classify maintenance tasks (preventive, predictive, corrective) and create standard task descriptions and estimated durations.
- Build a spare-parts catalog with part numbers, stock levels, lead times, and minimum/maximum quantities.
Definition: Preventive maintenance is scheduled work intended to prevent failures; corrective maintenance repairs failures after they occur.
Practical example: Create a task template for "bearing lubrication" with frequency, required parts, tools, and safety steps.
4. Maintenance Plan Preparation
- Define frequencies (time-based, usage-based, condition-based) and group tasks into schedules.
- Prioritize tasks based on risk and criticality to production or safety.
Practical example: For a compressor, schedule an oil change every 3 months (time-based) and a vibration check every 1000 operating hours (usage-based).
5. Work Processes and Forms
- Define work order lifecycle: creation, assignment, execution, verification, closure.
- Design standardized forms and templates for work orders, procedures, and intervention reports to ensure consistent records.
Definition: A work order is a document that authorizes and describes maintenance work to be performed on an asset.
Practical example: Ensure each work order includes safety permits, required spare parts, estimated hours, and sign-off fields.
6. Spare Parts Warehouse Procedures
- Perform initial warehouse inventory and set minimum and maximum stock rules.
- Define supply processes, receiving procedures, and issuance records for traceability.
Practical example: Use FIFO for consumable items and record batch/lot numbers for critical components.
7. Reporting Design
- Identify key reports required: backlog, overdue tasks, MTTR (mean time to repair), MTBF (mean time between failures), inventory turnover.
- Design report formats and schedules (daily, weekly, monthly) for operations and management.
Definition: MTTR is mean time to repair; MTBF is mean time between failures.
Practical example: A weekly report showing open work orders by priority and average completion time helps managers allocate resources.
Part 2 — Workflows and Implementation Sequence
- Prepare preventive and predictive maintenance strategies.
- Inventory spare
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Maintenance Technology Guide
Klíčové pojmy: Create a full asset inventory with consistent coding, Register personnel with skills and link certifications to tasks, Classify maintenance tasks: preventive, predictive, corrective, Build a spare parts catalog with stock rules and lead times, Define clear work order lifecycle: create, assign, execute, close, Design standardized forms and reports (MTTR, MTBF, backlog), Use sensors and historical data for anomaly detection and trend analysis, Apply AI to prioritize tasks and recommend interventions, Use AR/VR for training and step-by-step maintenance guidance, Implement an iterative cycle: monitor, analyze, predict, update, Prioritize tasks by equipment criticality and risk, Perform initial warehouse inventory and set min/max stock levels