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Asset management for Production Industry

Functions | Benefits | Range of Services


Manufacturing facilities and equipment as well as transport systems are exposed to high loads in production industry. To operate these assets economically, reliable condition information about the machinery is required. Our zedas®asset monitors your plants, generates diagnosis plus prognosis about plant performances, loads as well as wear and tear. The system controls compliance with process parameters or economic indicators (KPI) over the whole lifecycle of your assets (LCC).

Your resources are managed on this basis and according to your predefined maintenance strategy. Our zedas®asset automatically determines technical parameters (KPI) for the optimum control of plant services and operations. This way you are able to identify your plant capacity reserves and improve the operation. The system analysis historical plant data from operation and compiles forecasts out of the recorded data. As a result capex vs. opex alternatives, improvement potential for the operation of production facilities and efficient methods to increase the asset performance and extend their lifecycles will be provided.

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Function

zedas®asset:

  • Records faults plus their causes and compiles long-term analysis of the operative behaviour
  • Monitors inspections and the detected wear of assets or components
  • Compiles fault analysis from operating- and maintenance history
  • Determines asset or component load index using analysis of long-term process data
  • Management and planning of works using up-to-date loads and the asset maintenance history
  • Records personnel and material costs of maintenance activities

From lifecycle history of components and equipment zedas®asset determines:

  • KPI identifiers to enable condition-based maintenance
  • Cost history of maintenance and repairs carried out on assets or components
  • Forecast of costs for future (planned) maintenance works based on maintenance strategy

zedas®asset ensures:

  • Data recording from all production control and management systems without influencing the technology (e.g. SCADA, PLC, etc.)
  • Assistance for automatically operator and maintenance personnel instructions
  • Automatic checking of safety installations (e.g. limit switch)
  • Functional cockpits for assets (including overview of conditions and upcoming inspections, etc.)
  • Automated reporting and office integration

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Benefits for plant operations

  • Securing and improving conveyance performance:
    • Prevention of unplanned downtimes
    • Utilisation of capacity reserves
    • Optimisation of operation
  • Reduction in costs:
    • Flexibility of maintenance according to operational requirements
    • Planning of maintenance measures depending on up-to-date loads
  • Minimisation of planned plant downtimes:
    • Use of preparation time in case of in condition deterioration
    • Bundling and coordinating of maintenance measures
  • Support of fast decision-making processes
  • Development and use of a basis of knowledge to improve plant operation and maintenance
  • Enables increased performance and extended asset lifecycle

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Our range of services

Condition monitoring:

  • Data analysis, classification, alarming, long-term storage
  • Recording and monitoring of loads on main components and assets
  • Recording and forecasting of wear and tear

Workforce management:

  • Order planning as well as complex resource management
  • Coordination of maintenance and operation
  • Management of external service companies

Asset management:

  • Asset evaluation (overhaul vs. replacement)
  • Increased performance and extended lifecycle

Maintenance management:

  • Support of RCM maintenance strategies (corrective, preventative or condition based) at component and asset level
  • Allocation of work packages to individual components, assets or facilities for maintenance and inspection work
  • Recording of material and time demand for work orders
  • Allocation of work packages to qualification groups (e.g. electrician, welder, external)
  • Automatic calculation of scheduling for repetitive works taking into account load indicators for components, assets or facilities
  • Bundling of work packages to work orders or contracts
  • Categorised recording of fault causes with feedback of carried out works
  • Recording of actual costs including working hours and materials used (internal and external)
  • Analysis of fault causes on component, asset or facility level
  • Monitoring of component and asset warranties (guarantee monitoring)
  • Lifecycle records including maintenance history for components, assets or facilities
  • Storage management for spare parts plus forecast calculation of required spare part need
  • Calculation of MTBF (mean time between failure) and MTTR (mean time to repair)
  • Benchmarking of identifiers from maintenance for "asset comparison"
  • Archiving of all kind of documents (e.g. test certificates and recurring safety checks for components, assets or facilities, etc.)

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