XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUÇÃO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão.
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
IMPLEMENTED INFORMATION
TECHNOLOGY IN THE MAINTENANCE
SECTOR
Aurélio Zoelner Dallarosa (UTFPR)
[email protected]
Aldo Braghini Junior (UTFPR)
[email protected]
Luciano Scandelari (UTFPR)
[email protected]
Marco Antonio Subtil Macedo (UTFPR)
[email protected]
The implementation of a software for the maintenance management, in
a Chemical company, in the city of Ponta Grossa - Paraná - Brazil,
aimed to improve the Industrial Maintenance Sector, throughout the
register integration of predictive annd preventive maintenance from all
the factory’s equipment, as well as the Bills of Service, integrated by
this system. In seasoned companies, the biggest issue is keeping the
equipment, with many years of usage, without flaws; on the other hand,
the history of the equipment gives an aid to the manager when it comes
down to making a decision. In the new companies, the biggest problem
is to ensure the machineries function the same way as the seasoned
companies’ do, but, with a twist, the new companies do not posses
history, only the manufacturer’s manuals, transferring to the manager
the responsibility of making the right choice, avoiding the failure. This
responsibility becomes extremely subjective to the person and not to the
maintenance management. The main goal of this software is to help the
manager in the decision making, aiming at a longer and bigger life
endurance for the equipment, offering a lower cost to the organizations
of the company and also to control the performance of requester and
manager, becoming the study presented here.
Palavras-chaves: Software, Maintenance, Preventive, Predictive.
XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
1. INTRODUCTION
A Chemical company, located in the city of Ponta Grossa – PR, observed the necessity
to develop a maintenance software, seeing that the maintenance has the obligation to keep the
equipment supervised by it, trustworthy and safe for its users and operators, respecting people
and environment as a whole.
As said by Souza Jr. (2004) with the software’s help, the maintenance manager
receives the complete information, observing how its sector is and, acts not accordingly
his/her habits and behavior tendencies but, verifying problems, flaws and tendencies in some
specific cases and of bigger relevance to the organization.
Thus, the maintenance manager can verify and conduct his team to a dominant and
comfort situation when facing other sectors from the company, specially the production, for
this is the biggest direct client of maintenance, to fulfil its goals and answer the external
clients, between deadlines and specified qualities.
For this reason, the failure indicators, mechanic failures or even flaws that are
pinpointed by the system, could be extremely useful for all the organization or company, for,
with it, the manager can act ahead of the basic simple or complicated equipment defect, not
putting on disposition its function to the system.
For Campos (2006, p. 13) “a system is a processor formed by elements which interact,
whose input is information and/or energy and/or matter and which output is information
and/or energy to fulfil objectives”.
The Bills of Services are usually requested to the maintenance manager by an
electronic system, which means, any user can make a request register of Service or
improvement at the sectors who they work by the BS (Bill of Services).
These orders are registered in the system and the manager grants the access through
the users login, in order to obtain a better security and tracking of requests. These orders
follow a sequential number code, having a filter, per requester, area of work, area or sector in
which the equipment is located.
With the Bills of Service opened by the requester, the manager qualifies into
categories to indicate the priorities, and also, to verify the amount of working force, team’s
movement, control and programming of reposition parts regarding the warehouse.
Beyond the advantages mentioned that the software promotes to the maintenance
manager and the improving of quality in the production as a whole, another goal for this
implementation is to build a control list of the equipment and of the failures pinpointed by it,
remembering that in a recently built company, there is not such a register, making difficult the
immediate problem solution, sometimes very easy to be sorted out.
2. SOFTWARE FOR MAINTENANCE
The research was conducted in a multinational chemistry company, which was
recently built in the city. This company began its activities in November 2005, processing
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
Calcium carbonate, whose raw material is used in this company unit, coming by ship from
another unit, located in Turkey.
The carbonate is applied in the process of fabricating paper, as a mineral charge or as a
cover finishing print, giving more quality in the paper finishing, the bigger the carbonate
charge is. As an example we can mention the magazine paper.
In Ponta Grossa, the carbonate is prepared and delivered to companies in the paper
business, located in various states from Brazil: Paraná, São Paulo, Santa Catarina, Rio Grande
do Sul among others.
In order to achieve a customer assistance excellence, all companies search for various
solutions that provide quality and trust for the products generated by them. They seek the
costumer’s complete satisfaction.
“A management system is a compilation of inner related elements, used to establish
the policy and the objectives and to fulfil these objectives”. (ABNT, ISO 14001, 2004, p. 2)
Some companies, that are in the market for quite a while, go through the following
problems: their facilities are too old, their equipments are obsolete and are in need of frequent
technical inspections. On the other hand, when the companies are new, the problem is that
they do not posses equipment history and the only thing left for the manager are the manuals.
Many times there are performance comparisons from a similar equipment, however,
this practice can lead into mistakes, regarding the equipments do not react the same way in all
productions, in all factories, nor present exactly the same failures. As this company fits on the
second case, it was internally developed a system to manage and built a historic from all
equipment from the areas of:

Mechanics;

Electrics;

Instrumentation.
For the electrics and mechanics the maintenance are being programmed as follows:

Preventive maintenance;

Predictive maintenance;

Purification.
For the instrumentation there are some differences, due to calibration and instrument
verification, but also following the programming logic as in the other areas:

Checking;

Calibration.
The software is called Gman (Maintenance manager) and, this program generates all
the information in weekly and monthly reports format for all the areas. In the database is
possible to verify all the interventions on the equipments, which are separated according to:

Area;

Equipment;

Local;
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009

TAG;

Brand;

Sector.
In the picture below it is possible to verify the system’s structure, in which is possible
navigate to all sector departments, collect and/or alter information and equipment data in
general. Also, in this main screen, the manager as well as the users, can use to implement data
for the factory maintenance management department:
Picture 1 – Gman main screen
According to Kardec, (2002), verifying the types of failure, flaws or equipment
disabling for the process, it is also possible to obtain a history of each equipment, containing
the maintenance information conducted on it or the spare parts of each equipment. .
This equipment information are stored in the system database. The company basically
works with preventive and predictive maintenances in the equipments from the process.
On the next topic, the work instructions, the types of maintenance in the sectors of
mechanic, electric and instrumentation will be approached. The civil maintenance civil is
executed by an outsourced company.
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
3. SOFTWARE’S MAINTENANCE MANAGEMENT
Being the company a multinational and using imported technology, there is a certain
difficulty in the system’s deployment leading the maintenance team to have doubled attention,
avoiding nationalizing some equipments the wrong way. Plus the equipment is new and do
not posses a regular history. Thus, it is of great importance the monitoring, so that the
equipment have a longer duration and the sector shows security and reliability to the
production department.
This research will approach, as an example, only the mechanical maintenance
department, although, the system extends itself to other maintenance areas. Work instructions
regarding the mechanical maintenance operational procedures, in Ponta Grossa, will be
established.
3.1. Definitions and Abbreviations
- Gman – Maintenance manager
- Corrective maintenance – Takes place when the equipment breaks or there is a flaw.
- Preventive Maintenance – It is stipulated a deadline to execute the maintenance in every
equipment, given its history and work place.
- Predictive Maintenance – It is a type of maintenance, which evaluates the conditions from
the equipment, helping the preventive maintenance and upgrading the final cost.
- BS – Bill of Service;
- Crusher – Bricking area;
- Dry System – Tube’s mill;
- SMD – Base product tank;
- PX1 e PX2 – Aspheric mills, moist grind;
- Other System – Air compressor, water pump e chemicals in general;
- Load out – Shipment area of the final product.
3.2. Responsability and Authority
Mechanic – Keep the equipment running properly for the users, maintaining the
equipment running as requested via Bill of Service (BS), or accordingly maintenance
programming.
Technical Mechanic – Provides technical support to the mechanic maintenance,
doing technical sketches, technical planning, and the programming of the maintenance from
the equipment close to the production.
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
3.3. Activities Descriptions
3.3.1. Preventive maintenance
In the beginning of every month a list will be printed with the equipments which
inspections will reach their deadlines on that period of time.
On the deadline period from the preventive inspections, intervention and vibration
analysis reports will be analyzed, to evaluate the evolution from the rolling state. After this
procedure the equipment will have its intervention, if necessary.
If the inspection is not necessary, the planning reschedules the date from the
preventive maintenance and follows the equipment through predictive maintenance, until the
rolling ca not be used any longer.
Being necessary the inspection, a convenient date must be scheduled with the
supervision area. In the equipment inspection these are the procedures: turn off the engine,
request the removal of the fuse by the control file, unplug and take the equipment for
inspection. In case of centrifugal pumps, route for a outsourced company for the maintenance.
In the inspection the rolling conditions, rotor balance conditions, axis curve, braces,
gasket etc. will be evaluated.
After the inspection, install equipment, plug, execute lining (if necessary), request the
placing of the fuse, freeing the control file. Conduct test on the equipment and measurement
of functioning conditions after installation (noise, vibration, engine chain). When approved,
the equipment will be allowed to function.
Obs.: The reserve equipment remain without deadline for the next inspection and will
only be verified at the moment of use, by the maintenance system.
3.3.2. Predictive maintenance
Every month, the outsourced company, conduct the analysis of the equipment
vibration which affects the production and the quality of the process. After this analysis, the
company sends a report with the conditions of every equipment. This report has the objective
to inform the conditions of the monitored equipments during the month, showing diagnosis
and necessary recommendations, as well as the changes found when previous measurements
are compared.
In the vibration analysis measurements of velocity, acceleration and acceleration
package, collected by the velocity meter by the equipment bearing are taken.
The collected data are stored in a database of the company responsible for the measures
and they will be at the company’s disposal.
For the analysis result evaluation, the gathered values are divided into 03 (three) classes,
according to the vibrating levels found:
- Normal: Normal levels of vibration.
- Alarm 1: Values reaching alerting levels. No being necessary immediate intervention, but
requiring attention, for there is already a flaw.
- Alarm 2: elevated values of vibration, special attention being necessary and intervention as
quickly as possible to avoid equipment failure. In the analysis report, there are tendency
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
graphics for the equipment in Alarm 2.Analysing the graphics, the equipment that needs a
higher priority of maintenance is chosen. Thus programming with the area supervision the
equipment stoppage for the maintenance. To ease the management following the number of
equipments in Normal, Alarm 1 and Alarm 2 are presented in graphics by alarm type and by
frequency of flaws, and the diagnosis and recommendations for the fixing of the equipment in
alarm situation are synthesized in spreadsheets.
3.3.3. Users assistance
Frequently, when a factory sector, even when it is the maintenance sector, needs a
procedure of any kind done (corrective, preventive or predictive maintenance), it must request
it by a Bill of Service – BS, previously filled in at Gman. The executant area will do the
execution data programming, as a priority, the available manpower and the availability to stop
the machinery or equipment.
After the fulfilment of the service the executant(s) functionary(ies) fill in the date or
the dates (in case that the service lasts more than one day) when the services were fulfilled,
with the beginning time, ending time and the functionary(ies) registration(s). The functionary
must describe the service done to keep the equipment history. After the service’s conclusion,
the executing functionary, or just one of the executants registers the hours and the closure of
the BS at Gman, with the concluding and service time.
3.3.4. Registers
- Equipment history
- Preventive maintenance plan
- Concluded Bill of Service
- Bill of Service (pendent)
- Vibration analysis report
Through this structure the software is fed by the database so the system has enough
information for the manager and his/her team to develop all the activity within normality and
organizational programming.
After four years of operations, the factory unit presents a very satisfactory control
system, avoiding failures or equipment flaws. This software is being used in a simple and
regional way, regarded the database “Access 2003” is kept in a own company service and this
generates reports and other information to the maintenance manager. This, on its side, guards
the information and along with the team reaches the company’s goals, optimizing scheduled
pauses which, alongside the predictive maintenance follow, reaches a good ratio, better seen
on the table below.
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
Manutenções da unidade fabril - 2009
Corretiva
1,8%
Melhorias;
13%
Lubrificação
4%
Preventiva;
26%
Preditiva;
55%
Picture 2 – Maintenance types
4. CONCLUSION
This system took around one and a half year to be fully used. Today there is a control
man/time, the maintenance are separated by Preventive, predictive, Improvement and
Lubrification, stalled equipment statistics, machinery efficiency, tendencies and execution
plans.
The investments were only the development hours from the automation engineer and
his maintenance supervisor/engineer for the system’s implementation, nevertheless, the
purchase of machinery and training for the functionaries was vital. The result was quick
regarding the maintenance cost control in the last months, before and after the system’s
implantation, the comparison came as a 35% saving to the company’s organization, according
to the Chief Executive Officer.
Another important observation is that the company possesses another unit in São Paulo
and it is implementing one more in Três Lagoas, Mato Grosso do Sul. With an integrated
system, the companies can exchange experiences, verify spare parts in local warehouses,
among other relevant information of the areas.
According to Albertin (2004) by using current technologies, all systems can be
interlinked, expediting contracts, information, reports in many parts of the world, this last
option, making the companies working, basically, with manual and craft resources.
In the past, all the information were delivered by the conventional messengers and,
when it was necessary to inform a unit in another country, these information took a long time,
weeks even months until they reached their destination. Different from today, because with a
simple e-mail, the information are transferred from one place to another in minutes; in the
multinational case, the branches easily communicate with their matrix, as mentioned in this
article.
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XXIX ENCONTRO NACIONAL DE ENGENHARIA DE PRODUCAO
A Engenharia de Produção e o Desenvolvimento Sustentável: Integrando Tecnologia e Gestão
Salvador, BA, Brasil, 06 a 09 de outubro de 2009
This company is located in Ponta Grossa and its productive information are destined to
the matrix located in Switzerland or, to any part in the world showing an effective use of
technology, in other others, of IT (data processing).
5. REFERENCES
ALBERTIN, A. L; ABERTIN, R. de M. Tecnologia de informação. São Paulo: Atlas, 2004.
ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS – ABNT. NBR ISO 14001: sistemas de gestão
ambiental. Rio de Janeiro: ABNT, 2004.
CAMPOS, C. A. O. Uma proposta para a integração de sistemas de gestão. 2006. 139f. Tese (Doutorado em
Engenharia de Produção) – Universidade Federal de Pernambuco, Recife, 2006.
KARDEC, A.; ARCURI, R.; CABRAL, N. Gestão estratégica e avaliação de desempenho. Rio de Janeiro:
Qualitymark, ABRAMAN, 2002.
KARDEC, A.; FLORES, J.; SEIXAS. Gestão estratégica e indicadores de desempenho. Rio de Janeiro:
Qualitymark, ABRAMAN, 2002.
KARDEC, A.; LAFRAIA, J. R. Gestão estratégica e confiabilidade. Rio de Janeiro: Qualitymark,
ABRAMAN, 2002.
SOUSA Jr., J; CAMPELLO DE SOUZA, F. (Org.) Capitulo: Manias e modas gerenciais. Tópicos em
Engenharia de Sistemas. vol. 1 Recife UFPE, 2004
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