Enterprise asset management

GERSIS SOFTWARE Calgary-Houston-Berlin-Moscow

www.gersis-software.com

Property of Gersis software. http://www.gersis-software.com

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Enterprise Asset Management A suggestion for Maintenance Resource Optimization

With this suggestion, you may get ideas about how you can become a lot more

effective in using your available maintenance resources, save significant maintenance

cost, and increase the overall reliability of your assets.

As there are many different maintenance philosophies, we are not trying to solve every

problem with one standard solution, but rather address opportunities for real

improvements and real cost savings.

With only a few assets to take care of, you surely will manually manage your

maintenance tasks with the help of a simple Excel spreadsheet, MS Project, Primavera

or other planning tool.

However, with thousands of assets in different locations and very different maintenance

cycles, with hindering constraints, with in-house specialists and external contractors,

things might get a bit complicated in Excel. And expensive, if not handled properly.

Just to name a few examples:

If you build your in-house maintenance team big enough to stay in control even in

emergency situations, then there will be days when your team sits around idle. When

you build the team to cope with average historic workloads, emergency or even panic

situations could become difficult, and the teams are still idle at some times. Or, if you do

not group work orders with similar resources, tasks or locations, you waste time and

money.

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Our approach keeps a focus on:

Long term planning, for leveling all of your resources, and making sure you that you

have a plan with resources available when and where you need them, avoid over-

staffing for peak loads, or wasted idle times.

BEFORE, unleveled maintenance tasks/items are shown, as coming from the ERP system.

The huge differences in annual work come from scheduled shutdowns and

maintenance of part of the production system. Obviously, such a plan would never

work. Also obvious, manual scheduling of that many maintenance items would not be

realistic.

AFTER, the maintenance items have been scheduled optimally leveled, taking priorities,

existing resources and constraints into consideration.

Please note that the total nomber of maintenance tasks and items in the two diagrams

is not identical, as low priority tasks have been scheduled beyond the year 2022.

BEFORE

AFTER





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Short term planning, optimizing WOs (work orders) from the leveled long term plan by

using updated constraints and available resources, support what-if simulations and

send back the final WOs.

The Optimized WO may be sent back to the Planning or ERP system, directly to an

internal Work Center (Maintenance Department), or an external service provider.

The Asset Database may reside within the ERP or Planning System, or it may be part of

the Resource Optimization System.





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Long Term or Strategic Planning

The data from which the long term (1 year, 5 years, 10 years) or Strategic Preventive

Maintenance Plan is generated, come from existing Maintenance Items (MI),

equipment preventive maintenance docs, regulatory, statutory, legal, safety and

health requirements, Reliability Centered Maintenance (RCM), Risk Based Inspection

(RBI), Root Cause Failure Analysis Systems and possible other requirements.

Along with a resource (HR) forecast and available parts and tools, a Long Term

Preventive Maintenance Plan is calculated, with powerful planning algorithms finding

the optimal solution.

With this long term plan, peak loads or even emergency or panic situations can be

avoided, costly idle periods limited, and tasks with similar resources, location, tools etc.

have been grouped together.

Backed by this plan, the HR forecast can be optimized, you keep only those tools and

spare parts you need, and you alert subcontractors far in advance when and which

services are needed.

Any change in your assets, strategy, or resources, simply requires a re-run of the

planning software.

Even for several hundred thousand assets and MIs, this can be done within a few hours,

the core optimization within minutes.

Short Term or Tactical Planning

Short term planning focuses on daily, weekly or perhaps monthly execution needs.

The Maintenance Scheduler optimizes WOs from the leveled long term plan by using

updated constraints and actually available resources. With what-if simulations he can

find the most optimal WO, and then submit it to the ERP system or directly to the internal

Work Center or external service provider.

In a system we built for an Oil&Gas company, the time required to schedule 1,000 work

orders took about 15 minutes.

Our Offer

An experienced maintenance consultant will provide a comprehensive analysis of your

current situation, with the target of significant reliability improvement and cost savings

Based on this analysis we jointly work out a realization plan. This might be followed by

development of a detailed Requirements Specification for a long term improvement

plan.

Any software part of such a plan can be architected and built by us, tailored to your

needs, and using our domain experience.

Finally, we support you for installation, rollout, user training, and ongoing improvements.





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Conclusion

As mentioned before, there are different maintenance strategies, and different

optimization opportunities.

We have the expertise to build a system addressing your particular needs, whether

currently you’re planning manually with PC tools like Excel, whether you use SAP to

generate unleveled Maintenance Plans, or whether you use advanced systems like

Meridium or Cassantec.

We are happy to discuss any opportunity to improve your Maintenance effectivity.

We care of your business!

CEO

Gersis software S. Artsimenya


Technology

Enterprise asset management