Programming and Maintenance: The synergy between APS and PMS
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Thinking of theory, maintenance management and production programming seem to be very intimate and interconnected processes, after all they manage many common resources and have the same objectives of increasing their availability and efficiency. However, the integration between them is little explored in the current practice of Brazilian industry. And I understand: Both areas have very leared people resources and a future visibility, with great uncertainty, which, unfortunately, management needs to be as simple as possible, focusing on what is most critical, urgent and known . Limitation on low visibility who works with TPM (Total Productive Mainance, or total productive maintenance) already has a more solid base for joint action with PPCP because within its pillars are planned maintenance, whether preventive or predictive. However, this planning is performed and usually is within the maintenance area and the information is unlikely to the PPCP in a formal way. The information comes on a phone call, a meeting, or in a corridor conversation, when the areas interact and maintenance informs, “ Look, PPCP, Machine X will have a 4-hour maintenance next Thursday at 14h. ” This situation is aggravated for those who do not use APS software , because even if the maintenance plan has a higher horizon than a week, the PPCP itself has no more than a few days in their own production programming. So the maintenance that is later does not have a clear use. Finally, this scenario of low visibility and programs accuracy limits the synergy between the areas. On the other hand, when we have a production programming through the APS , we can improve these processes. APS + PMS for planning when you start using Opcenter APS , a very interesting point to see the finite production capacity is to bring planned maintenance to the Gantt chart so that they are already considered when in the image below. Thus, an operation cannot be programmed at this time in an appeal that will already be committed to maintenance.
Figure 1 - Gantt Preprogramming with predictive green and preventive maintenance in orange
Opcenter APS key user , but ideally they can be imported from another system, whether the MEP, Mes or Specialist Maintenance System Module. A next step of synergy can arise when maintenance need not occur exactly on that specific day and time, but in a certain ideal period. Thus, the exact allocation of maintenance can be performed after the PPCP analyzes the production programming itself . For example, predictive maintenance software can inform the APS when it will be maintenance and already fixed them on the horizon as shown in Figure 1, but it could also create a maintenance request to be allocated in a given period, and that would have its exact day and time allocated by PPCP in APS, respecting the limits indicated by maintenance and seeing the best time for the minimum possible to damage the production. Synchronism between operations and shifts of each feature is considered in the APS, it is possible to see situations where maintenance allocated in the morning or afternoon shift changes productive efficiency. Even this impact on efficiency can occur not only for the appeal that will undergo maintenance, but also for later operations that depend on the production of that resource. That is, the conversation between what maintenance needs and what PPCP needs through an integrated programming enhances efficiency gains. It is clear that making this change is not simple, you need to have a well -structured process, with guardians and deadlines for these new activities, as well as add more layers of integration between systems, as PHC will return the scheduled maintenance dates as well. Still, efficiency and better visibility gains favor the initiative.
Potential gaps for maintenance fitting
Figure 2-Post-program gantt with potential gaps for maintenance allocation
But what about corrective maintenance? Corrective maintenance may be the most critical to be contemplated in integration between APS and EPR or month , given the urgency of agility in the response that PPCP needs to have when an unforeseen machine breaking occurs and the impact that the problem can generate. But because of the urgency and scarcity of resources to standardize processes, many industries solve these problems outside the system. First, this is a problem for its own maintenance because there is no history of stops and impairs indicators such as MTBF (Mean Time Between Failures ) and MTTR (Mean Time to Repair) . Second, if this does not go into system, APS will depend on a manual intervention of the programmer to insert corrective maintenance and perform production reprogramming from it. This manual process is viable, but it loses agility . A good integration between ERP or month with APS allows a corrective maintenance event to occur, APS may already block the resource during the time expected for diagnosis, MTTD (Mean Time to Detect) , as well as updating the duration of maintenance according to the MTTR predicted to that type of problem, as it was diagnosed.
Figure 3 - Gantt with Red Red Programming and Corrective Maintenance with automatically imported by MTTR
It is important to understand that very short stops probably do not impact production programming (nor reprogramming), as they are very short -term events without sufficient expression (the impact of these problems can be measured by adherence to programming ). However, larger stops or extremely critical resources may require an immediate response and this agile integration can become a great differential. So, did you like the content?
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