Real-time performance metrics, data acquisition and production analysis are at the heart of manufacturing—whether process or discrete manufacturing—as companies rein in new plant spending and focus on utilization. Real-time systems are becoming more accessible for many divisions within the factory, and maintenance applications are no exception.
For years now, computerized maintenance management systems (CMMS) have been making inroads in industry as management moves away from inefficient paper-based approaches and toward electronic work orders. Now, cloud-based CMMS platforms are making it even easier for enterprises to scale a new maintenance process to many plants or warehouses.
To more effectively track work orders, provide maintenance technicians more resources on the plant floor and manage inventory more efficiently, Raleigh, N.C.-based Pepsi Bottling Ventures (PBV) installed MaintenanceEdge, a cloud-based CMMS platform fromDude Solutions, in stages over the past three years at multiple facilities, including bottling plants and warehouses.
PBV项目工程经理戴尔·斯坦（Dale Stein）表示：“零件管理的易度性并能够在几秒钟内找到零件，而不是在某些情况下20-30分钟的问题使我的生活变得更加轻松。”该公司在北卡罗来纳州加纳的装瓶设施现在根据库存管理模块的历史趋势计划零件订单。
With such changes to the maintenance workflow, PBV asked Dude Solutions for advice on how to upgrade its paper-based preventive maintenance (PM) approach and move toward real-time maintenance. “We took the output of their older PM program, with all the tasks and inventory list, and redeveloped their approach with the new CMMS platform,” says Dwayne Divers, vice president of client success at Dude Solutions. “We consolidated workflows to reduce the number of work orders. And, going forward, PBV can make modifications on a continuous basis.”
基于云的维护范围软件作为服务（SAAS）提供了在线工作订单管理套件；它还具有通过资产层次结构组件识别关键设备的能力。使用此工具，PBV启动了350,000平方英尺装瓶设施的资产层次结构和实施，预防性维护和纠正性维护。
“The CMMS makes it very easy to run work reports and retrieve the data when it comes to our audits,” Stein says. “The reporting really helps me trend out performance on the equipment.” The bottling facility can have as many as 76,000 work orders at any one time.
With the asset hierarchy and implementation piece of MaintenanceEdge, a large bottling facility can start the journey to equipment optimization. “The solution provides the ability to establish a parent/child relationship between equipment,” Divers says.
A company can start at the line level in a process plant, Divers explains. In the case of a bottling facility, this could be a filler, capper or labeler. From the parent level, the software maps out specific child components of a machine center, such as a valve on a filler or a conveyor segment.
“With PBV, we started at the line level and drilled down into the machine centers,” Divers says. “We didn’t get into every valve on a filler, but we did get into the major components of the filler, with a detailed view of these components for a maintenance technician or plant manager.” This process is the first step in accumulating equipment data and eventually being able to do failure analysis.
The application also provides the ability to view a specific piece of equipment and history of the failure and see the work that’s been done on that asset. It also moves into higher levels of the asset hierarchy—parent/child—so a manager can compare maintenance costs between two bottling lines.
通过PBV的这种数字转换，维护技术人员现在触手可及的资源更多，饮料生产商为他们提供了完整版本的平板电脑。在预防性维护或纠正措施中，维护技术人员可以通过工厂地板上的平板电脑查看该设备的接线图，零件清单，工作历史记录或爆炸零件视图。可以设置权限级别以使用户可以访问编辑数据库记录和字段。
通过将特定的工作订单分配给维护技术人员，PBV希望通过平台的利用率指标更好地了解工作订单流程。潜水员解释说：“跟踪机制为技术人员的利用提供了更好的信息，并强调了工人对数据获取的需求，以便工厂收集对设备的更丰富数据。”PBV还实施了一张热图，该热图着眼于整个设施中不同类型的工作和设备花费的小时数，并提供了维护仪表板进行管理。
With the dashboards in place for PBV’s management, the business should be ready for more maintenance efficiency pops in the world of soft drink production.
