Maintenance & Safety:

ENGG ZC242
BITS Pilani
Pilani Campus

Girish Kant
Department of Mechanical Engineering

BITS Pilani
Pilani Campus

Maintenance Integration
CHAPTER 11, Lecture -16

Learning Objectives
Various steps in integration

Integration of e-business software with ERP

Future Trends in Integration

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INTRODUCTION

In the present day the outlook for manufacturing

appears relatively bright. However, some of the
challenges are expensive investments in new facilities,
increase in international competitions, etc. Therefore,
manufacturers look for leveraging the processes by
improving their efficiencies.

One of such attempts is integration of maintenance

functions with engineering, procurement, and overall

supply chain management.
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Steps in integration

Various steps in integration are as follows:

1. Aligning the engineering and maintenance functions
under production umbrella.
2. Involvement of maintenance staff early in the concept
and design phase itself.
3. Awareness to production / machine specification.

4. Third party consultancy assistance.

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Steps in integration
5. Integration of e-business software with
enterprise resource planning Packages, like

SAP
6. Integration of CMMs with process control data.
7. Periodical meetings, once in a week or month
between various departments in the
organization.
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Aligning the Engineering and

Maintenance Function
Creating efficiencies in maintenance and engineering
functions is a first step toward improvement.
By

more

closely

aligning

the

maintenance

and

engineering activities within production operation the

efficiency and machinery performance can be taken to an

even higher level.
Most

manufacturers

engineering

and

facilitate

maintenance

collaboration

functions

between

although

companies have traditionally managed each separately.

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Involvement of Maintenance
Staff Early
One of the first and easiest ways you can overcome

long-standing inefficiencies is to involve engineering

and maintenance-support engineers during the product
design, development, manufacture installation and
operate phases of any project.
Active participation from both the groups is effective
method

of

designing

and

optimally

maintaining

production equipment.
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Awareness to Production /
Machine Specification
Maintenance personnel must be better informed about

the production specifications and operating parameters

of plant-floor equipment.

Very rarely plant equipment operates at 100% capacity.

When a problem occurs, maintenance teams often
repair the equipment to its most recent production levels
but not to the machine's optimal design capacity.
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Third Party Consultancy

Assistance
To help the maintenance and engineering staffs
collaborate more effectively, many manufacturers use
third-party consultants to provide the insight into
opportunities for process improvements and synergies.

Understanding your organization's unique challenges,

engineering

service

providers

help

integrate

engineering and maintenance to maximize uptime and

optimize ROI (Return on Investment).

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Integration of e-business
Software with ERP
Integration of e-business plant maintenance solutions

with

SAP

functionality

systems

provides

the

needed

by

maintenance-driven

large

supply

chain

organizations while providing all of the transaction

details required for complete financial control.

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Integration of e-business
Software
With the e-business plant maintenance software-SAP
integration solution, businesses realize critical business
benefits including:
1. Maximizing returns on assets
2. Improving throughput
3. Creating workforce efficiencies
4. Satisfying regulatory compliance while assuring
proper financial accounting.
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Integration of e-business
Software
Unfortunately, many manufacturers fear about the
initial investment of time and money required to
implement key engineering and manufacturing
improvements.
Short-term expenditures of personnel and other
resources are the biggest obstacles. While these upfront costs generally last for only the first 12 to 18
months of implementation, many manufacturers have
reported substantial returns after 18 to 36 months of
functional integration.

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Integration of e-business
Software
Advantages of close cooperation between engineering
and maintenance are:

1. Lower costs
2. Improved process efficiency

3. Better machine operation and output.

With the equipment operating at optimal design capacity,
production costs are drastically reduced. The total cost
of equipment drops, and the organization can increase
overall manufacturing capacity without adding floor
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space.
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Integration of e-business
Software
Although integration requires an up-front investment,
bridging

the

gap

between

engineering

and

maintenance can reap substantial, long-term rewards

for all types of manufacturers in facilities around the
country.

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Integration of e-business
Software

Scheme for Integration of maintenance function with other

functions.
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Integration of e-business
Software

Monthly meetings help integration with engineering/design

functions.
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Integration of e-business
Software

Integrated maintenance excellence in an Industry.

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FUTURE TRENDS
There are immense benefits of integrating the two
data structures, one collected from condition
monitoring and the other from CMMS.

There are significant benefits that can accrue from

integrating process control data with condition
monitoring data.

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Example
For example, certain electric motors may display
higher vibration when operating under low loads, than
when they are operating under high loads.
In the traditional methods of vibration analysis, using
periodically collected data, using a hand-held data
collector, these variations are not effectively taken into
account, except perhaps in a qualitative manner.

Slight variations in vibration results from one survey to

the next are assumed to be due to process conditions,
and regarded as not significant.
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Example
If we were able to collect relevant quantitative data
regarding the process conditions existing at the time
the vibration data was collected, and correct the
vibration data for these conditions, then our diagnostic
capability would become far more accurate and
sensitive.
Presently, this is not the case. Analyst's experience
becomes more important in arriving at accurate fault
detection and failure prediction.

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Example
In order to achieve greater integration, we need
integration of these data sources.

It is necessary and desirable that each of these

systems should be able to interface with one another
using common standard protocols.
It may be feasible to interact with condition monitoring
suppliers who can offer integrated condition
monitoring software, which permits the effective
integration of oil analysis, vibration analysis and other
condition monitoring data into combined reports.
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Example
Similarly, it should be feasible to interact with CMMS
vendors, so that they can include a condition
monitoring module within their software.
However, an effective solution is yet to be developed
as a whole.
Some of the integrated software presently used in
developed countries, allows only for high-vibration
alarms on permanently-monitored equipment to be
displayed on operators' control panels (or more
accurately, computer screens).
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Example
Research and trials are, in progress currently to use
equipment performance data collected within the
process control systems in order to optimise and
maximise total system performance.
If permanent on-line vibration monitoring is required
for anything other than an overall vibration alarm, the
cost of providing the required communications
infrastructure and the data collection and analysis
equipment is prohibitive.

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Example
However, when fully developed smart sensor
technology will greatly reduce the complexity of
linking the outputs of the condition monitoring sensors
to current process control systems.
More and more equipment will be able to be
monitored continuously, on-line.
Control room operators will be able to tell, quickly and
easily, the current condition of the bearings or
alignment or balance or gears on a particular
machine.
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Example
It may be necessary to develop expert systems for
fault diagnosis.
The reality is that these expert systems tend to be
weaker than even a moderately experienced vibration
analyst in identifying and diagnosing faults.

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Example
Nevertheless, if smart sensor technology is to work,
and if widespread on-line vibration monitoring is to
proliferate, it is the development of better, and more
accurate, expert software.
The users may look forward to see further advances
through the use of fuzzy logic and neural network
processes in condition monitoring software.

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Integration of ERP

Block diagram showing integration of ERP with asset

management system and production forecasting scheduling
system.
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Integration of ERP

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Integration of ERP
Such integration through a block diagram where in the
three systems, namely:

Enterprise asset management system,

Supervisory control and data acquisition system which
becomes a base for production forecasting and
scheduling system, and
Enterprise resource planning system work in tandem
to have absolute integration and management of
supply chain effectively
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Thanks..

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