Eliminating sources of maintenance losses
First Claim
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1. A process for simultaneously addressing multiple sources of maintenance profits and losses, the process comprising:
- a. entering, using a computer, historical data regarding one or more assets and if historical data is not available entering estimated data regarding the one or more assets;
b. classifying and calculating at least one Maintenance Profit &
Loss parameter for the one or more assets using said computer;
c. generating a ranking list of the one or more assets using said at least one Maintenance Profit &
Loss parameter;
d. developing and optimizing work order tasks based on the ranking list, wherein those one or more assets with the highest rank maintenance profit and loss have work order tasks developed from 5S for Machine/Maintenance (5S4M), 5S for Production/Process (5S4P), and measurement technologies (MT) that are larger in number of said work order tasks and are according to asset type of said at least one or more assets and further wherein those one or more assets with the lowest rank maintenance profit and loss have work order tasks developed from 5S4M/5S4P/MT that are lower in number of said work order tasks and are according to asset type of said at least one or more assets;
e. using a slope generated by trends in said measurement technologies by said asset type to trip alarms that identify problems, wherein the higher at least one asset is in said ranking list, the tighter the slope required to trip an alarm;
further wherein the lower at least one asset is in said ranking list, the broader the slope required to trip said alarm;
f. generating an integrative work order including at least said developed work order tasks, an integrative graph displaying said trends in said measurement technologies, said tripped alarms, and said at least one Maintenance Profit &
Loss parameter;
g. managing at least testing, trending, and repairs based on said integrative work order;
h. classifying said work order tasks according to scheduled or unscheduled repairs, consequences and task origins including Machine Process People (MPP);
i. using data from said work order for analyzing said multiple sources of maintenance profits and losses and generating tools for training, analysis and communication; and
j. using said computer for displaying a number of instructions and providing feedback for users to address said multiple sources of maintenance profits and losses.
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Abstract
Processes and software are provided for eliminating sources of maintenance losses in machine intensive environments such as manufacturing, processing and assembly plants.
The processes and software include creating financial and work order metrics to trend maintenance variables, a process for creating work orders, a process for using alarms for integrating measurement technologies and spare parts, a process for managing repair and replacing activities and projects by improving documenting and communicating processes while involving users such as executives and senior managers.
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Citations
11 Claims
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1. A process for simultaneously addressing multiple sources of maintenance profits and losses, the process comprising:
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a. entering, using a computer, historical data regarding one or more assets and if historical data is not available entering estimated data regarding the one or more assets; b. classifying and calculating at least one Maintenance Profit &
Loss parameter for the one or more assets using said computer;c. generating a ranking list of the one or more assets using said at least one Maintenance Profit &
Loss parameter;d. developing and optimizing work order tasks based on the ranking list, wherein those one or more assets with the highest rank maintenance profit and loss have work order tasks developed from 5S for Machine/Maintenance (5S4M), 5S for Production/Process (5S4P), and measurement technologies (MT) that are larger in number of said work order tasks and are according to asset type of said at least one or more assets and further wherein those one or more assets with the lowest rank maintenance profit and loss have work order tasks developed from 5S4M/5S4P/MT that are lower in number of said work order tasks and are according to asset type of said at least one or more assets; e. using a slope generated by trends in said measurement technologies by said asset type to trip alarms that identify problems, wherein the higher at least one asset is in said ranking list, the tighter the slope required to trip an alarm;
further wherein the lower at least one asset is in said ranking list, the broader the slope required to trip said alarm;f. generating an integrative work order including at least said developed work order tasks, an integrative graph displaying said trends in said measurement technologies, said tripped alarms, and said at least one Maintenance Profit &
Loss parameter;g. managing at least testing, trending, and repairs based on said integrative work order; h. classifying said work order tasks according to scheduled or unscheduled repairs, consequences and task origins including Machine Process People (MPP); i. using data from said work order for analyzing said multiple sources of maintenance profits and losses and generating tools for training, analysis and communication; and j. using said computer for displaying a number of instructions and providing feedback for users to address said multiple sources of maintenance profits and losses. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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Specification