Maintenance controlling

Technologically advanced and flexible production facilities for large quantities require very high investments. In order to ensure their profitability, maximum availability for high utilization of the production facilities is therefore essential. This availability is ensured by maintenance, in which all measures required for this are planned, controlled and carried out.

In automated and linked production facilities, loss of use occurs due to technical malfunctions in the machines themselves and due to malfunctions in the linkage.
Durch mangelnde Kenntnis der Störursachen und deren Folgewirkungen werden häufig falsche Maßnahmen zur Störungsbeseitigung gewählt. Wirksame Instandhaltungsstrategien können nicht entwickelt werden. Dies führt oft über lange Zeiträume zu andauernd uneffektivem business der Produktionseinrichtungen.

Therefore, a targeted recording of faults and process data monitoring is indispensable.This should achieve:

• Increase in maintenance transparency in order to ensure quick decisions on troubleshooting,

• statistische Auswertung und Aufbereitung der Stör- und Prozessdaten zur Weak point analysis sowie zur Steuerung der Instandhaltungsaktivitäten und

• Integration of the processed data in a controlling concept.

In most companies, the state-of-the-art, preventive inspection strategy has established itself as the state of the art: The actual state is determined via inspection, the target state is secured via care and maintenance. The target state is restored via repairs.

This strategy assumes that considerable amounts of data are processed and managed using master and transaction data.

Typical master data are, for example:

• Machine number, cost center;

• Building,

• Location,

• Target process data, such as
- cycle time,
- temperatures (max., Min.),
- prints (max., Min.);

• quality data,

• Spare parts stocking.

Typical movement data (current and documented) are, for example

• workpiece / type,

• number of items good,

• Bad number,

• start of disturbance / disturbance,

• cause of malfunction,

• Data for recording repair costs
- repair wages times,
- Material costs, spare parts;

• Actual process data, such as
- cycle time,
- temperatures,
- prints,

• Quality data.

The recording of malfunction data or the recording of process data is the original data source from which the maintenance controlling is fed, with the task of ensuring the maintenance to ensure the availability of the production facilities with minimal maintenance costs.

A CIM concept (CIM implementation strategies) without maintenance controlling is an incomplete approach. In the case of capital-intensive production facilities in particular, the lack of availability has a serious impact on capacity.

High availability, secured by fast-acting measures for troubleshooting, are a prerequisite for the profitability of the production process.

In principle, all interfaces for fault data and process data acquisition are available in a CIM solution. This means that not only the data required for maintenance controlling are available, but the entire controlling field from production control to accounting can be served.

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