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COMMON USE OF COMOS MRO WITH PCS 7 FOR EFFICIENT MAINTENANCE
Internal Supervisor: Prof. Dr. -Ing. Habil Reiner Staudt
External Supervisor: Dipl. -Ing. Dirk Grützmann
Master of Process Engineering (MPE)
Esma Ezgi Küren
January 24, 2020
OUTLINE
Introduction
- Demonstrate the benefits of digital transformation in maintenance management
- Improve the plant maintenance and operating performance by common use of COMOS MRO and PCS 7
- What is maintenance and why it is important?
17 days/year
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HOW DO YOU MANAGE DATA?
Process Engineering
Electrical Engineering
System Engineering
Piping and Instrumentation
Automation
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COMOS
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- Process engineering
- Pipe specifications
- Isometrics
- Electrical, instrumentation & Control and control system engineering
- Automation
- Pneumatics and hydraulics planning
MRO
- Virtual Reality training and simulation
- System-independent and mobile access to all plant information
- Service and maintenance management
- Shutdown and modernization management
- Inspection management
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USER INTERFACE
Menu Bar
Navigator
Working Area
Detail Window
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PCS 7
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OUTLINE
Introduction
Approaches
&
Results
Research Questions
Future Improvements
- What are the requirements for efficient maintenance in industrial plants?
Research Questions
- What is the present status of maintenance operations carried out in industrial plants?
- How to digitize and make maintenance operations more efficient by using COMOS MRO?
- What data are collected and how are they used in COMOS MRO with PCS 7?
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OUTLINE
Introduction
Approaches
&
Results
Future Improvements
Research Questions
What are the requirements for efficient maintenance in industrial plants?
- Gathering & analyzing data to define the needs and the problems of the plant:
-Machine downtime, asset behavior, intervention history, etc.
- Creating a maintenance plan:
-Distribute the daily tasks between the teams
-Plan & control the machine stops
- Managing spare parts:
-Essential part of a completed quality maintenance program.
-The most important factors to be considered;
Consumption history
Spare part delivery times & costs
- Maintenance staff:
-The creation of skilled maintenance staff
-Trainings
Approaches &
Results
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What is the present status of maintenance operations carried out in industrial plants?
-Run it until it breaks! (Reactive/Corrective Maintenance)
Most facilities do not expend the necessary resources to maintain equipment in proper working order.
-Preventive Maintenance
Less equipment downtime
Potential for over maintenance
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MORE THAN 55% OF MAINTENANCE ACTIVITIES OF AN AVERAGE FACILITY ARE STILL REACTIVE IN NATURE!
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How to digitize and make maintenance operations more efficient by using COMOS MRO?
- Industry 4.0 - Maintenance 4.0
- e-Maintenance:
Internet of Things (IoT): -Communication of devices with minimum human intervention
-Advanced diagnostics and maintenance decision support
Virtual or augmented reality:
-Taking actions before a failure occurs (Predictive maintenance)
-Monitoring, collecting, recording, and distributing real-time data
- COMOS MRO as a CMMS (Computerized Maintenance Management System):
Maintenance, Repair & Overhaul
Management, planning, and organization of operation and maintenance, including plant documentation
in a single system
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Planning and organizing maintenance tasks
COMOS MRO
Collecting and processing the entire technical information
Option of updating data
Option of controlling maintenance tasks that are not planned with COMOS
Option of including maintenance aspects as early as in the planning phase
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MAINTENANCE OPERATIONS IN COMOS
- WHEN? Planning on maintenance plan
- WHAT? Work description on work package and activity
- WHERE / WHO? Needed qualifications and person
- Planning & Feedback over subject structure
Maintenance plan
Work package
Activity
Qualification
Person
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DATA CONSISTENCY
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COMOS MRO supports all established maintenance strategies!
1
3
4
2
RISK BASED MAINTENANCE
PREDICTIVE
MAINTENANCE
PREVENTIVE MAINTENANCE
CONDITION BASED MAINTENANCE
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What data are collected and how are they used in COMOS MRO with PCS 7?
- Fluid on the ground..
(B001 Vessel)
- Unusual sound detected..
(P001 Pump)
- Unusual smell detected..
(P001 Pump)
- Leakage detected..
(P001 Pump)
(THERE IS NO NEED OF DATA SELECTING OR COLLECTION FROM DIFFERENT SYSTEMS AND COMBINING IN SPREAD SHEETS !)
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- Example: "Pump Cavitation"
- Procedure:
- Maintenance task is handled electronically
- Result:
- Unexpectedly failed asset will be repaired as quickly as possible
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Integration between "Automation level" and "Enterprise-Asset-Management-System"
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OUTLINE
Introduction
Approaches
&
Results
Research Questions
Future Improvements
As a process engineer, I want to..
- Improve a new interface between COMOS MRO and PCS 7
so that..
- The relevant maintenance operations could be performed with minimum/without human intervention
NEW PRODUCT
in order to..
Future Improvements
- Reduce work load of maintenance personnel
- Save effort and time
- Increase the efficiency of maintenance activities
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REFERENCES
- VIEIRA, D.R. and LOURES, P.L., 2016, Maintenance, Repair and Overhaul (MRO) Fundamentals and Strategies: An Aeronautical Industry Overview.
- Shafiee, M. and Chukova, S. 201. “Maintenance models in warranty: A literature review”. European Journal of Operational Research, Vol. 229: 561-572.
- Raju V.R.S., Gandhi O.P., Deshmukh S.G., 2012, Maintenance, Repair, and Overhaul Performance Indicators for Military Aircraft, Defence Science Journal, 62(2), 83-89, doi:10.14429/dsj.62.881
- Siemens AG, 2020, My Presentation Manager, Siemens AG, viewed 15 Jan 2020, <https://intranet.industry.siemens.com/mpm-sim/>
- Schleicher M. and Blasinger F., Control Engineering-A guide for beginners, Fulda, Germany, JUMO GmbH & Co. KG, 2003. Print.
- Sullivan G. P., Pugh R., Melendez A.P., Hunt W.D., 2002, Operations and Maintenance Best Practices, Pacific Northwest National Laboratory.
- COMOS Getting Started Manuel, Siemens AG Digital Industries, Nürnberg, Germany, 2019.
- COMOS MRO Manuel, Siemens AG Division Process Industries and Drives, Nürnberg, Germany, 2019.