Asset Management

A CMMS software package maintains a computer database of information about an organisation's maintenance operations. This information is intended to help maintenance workers perform their jobs more efficiently and help management make informed decisions.

CMMS packages offer a wide range of capabilities and cover a correspondingly wide range of prices:

• Work orders
• Inspection
• Preventive maintenance
• Machine breakdown
• Asset management
• Inventory control
• Safety

„TP Engineering" has developed their own CMMS called TP.AIM and also has experience and agreements in place to implement IBM Maximo and SAP PM systems if preferred.

"TP Engineering" has been involved in many projects related to the preparation, planning and scheduling of shutdowns and maintenance activities of industrial enterprises using our own unique planning system.

The uniqueness of our system is “the planning from the bottom to the top” principle based on engineering information , required for  safe and efficient solutions of the maintenance tasks (for the maintenance task to be performed safely and efficiently).

This information includes:

• Location of maintenance implementation;
• List of equipment in need of maintenance;
• Maintenance time;
• Written instructions that shall be used;
• Which documents are needed (descriptions, instructions, drawings, spare part catalogues);
• Tools and measurement instruments to be used;
• Any necessary handling and transport equipment to be used;
• Expected spare parts to be used;
• Number of qualified workers (including contractors);
• Any special safety rules to follow;
• A list of contact persons from the customer for getting work permits.

Defect Elimination

Our loss analysis program utilises a 5-step method (Register>>Analyse>>Investigate>>Solve>>Improve) that ensures all the data pertaining to deviation from desired business objectives is captured and acted upon in a timely manner.

The losses are investigated through a Root Cause Analysis (RCA) process which is facilitated and effective solutions are determined. These solutions are then tracked and closely monitored for the benefits made to your organisation. The payback for a loss analysis program is often measured in days or weeks due to its rapid rate of return.

RCM - Reliability Centered Maintenance

RCM, is a process to ensure your assets continue to do what they require in their present operating environment and put in place optimal failure management strategies

RCM is used to achieve improvements in fields such as the establishment of safe minimum levels of maintenance, changes to operating procedures and strategies and the establishment of capital maintenance regimes and plans.

Successful implementation of RCM will lead to an increase in cost effectiveness, machine uptime, and a greater understanding of the level of risk that the organisation is currently facing.

Once the maintenance strategy has been determined, the asset can then be optimised to maximise operational throughput by aligning these plans and identifying their impact on production and current equipment configurations.

This is provided through:

• Identification of bottlenecks
• Increased availability of new or existing units
• Reducing defects during designing process
• Optimising spare part holding in inventory
• Reducing downtime necessary to perform maintenance activities

A common technique to optimize plant availability and capacity is through the construction of Reliability Block Diagrams (RBD).

Data captured from your CMMS is readily converted to meaningful parameters that can be simulated over a pre-determined lifetime as  models to predict asset performance over multiple types of operational scenarios.

Spare parts become an integral part of optimization when it comes to the further increase in the efficiency of the maintenance processes.

It is essential that the parts on hand be adequate to meet the needs of all work in progress and emergencies, so that each maintenance function be fully served, not too many, not too few.

Slow-moving spares are generally responsible for a large part of the inventory value of any organisation. They tend to be expensive and, although only accounting for perhaps 20% of the inventory items, they often represent 60-80% of the inventory capital tied up.

The optimal spares holding level will minimise the amount of unnecessary procurement and reduce excessive inventory space.

In turn, not holding the part can also increase the risk exponentially for critical equipment that may cause outage for extended period.