Professional maintenance – Machine ledger
The Machine ledger is a module that is part of the World Class Manufacturing methodologies (WCM). The Machine ledger is designed for professional maintenance.
The purpose of the Machine ledger is to keep the maintenance of the machinery under control, revealing the root causes of the faults, while at the same time feeding a historical archive.
But above all the NeXT Machine Ledger module continues in the direction indicated by all the other software modules, of a global data computerization, i.e. the progressive replacement of the chart with digital supports, that are therefore immediately available and, above all, queryable.
If we want to define the Machine Ledger in a simple but clear way, we can define it as follows:
It is the totality and the coordination of all the activities designed at the component level,
in perfect harmony with the current WCM standards.
Going deeper, we will say that it is characterized by:
- the disassembling of the machine into functional groups. Each component of the machine is classified according to its importance for the operation of the machine itself (class A, B and C).
- from information regarding the maintenance policies to be applied
The Machine Ledger is a software module that provides two situations, two main features:
- Implementation of the Machine Ledger information system at the customer’s plant.
- Realization of a web portal accessible to the machine suppliers, through which they will be able to send the customer the specifications of scheduled maintenance in the Machine Ledger
The web portal
Through the web portal the suppliers can send the specifications of the maintenance to be carried out.
These specifications will indicate:
- Machine name
- Belonging group
- Subgroup of the machine parts
- Each component of the subgroup will be identified by a code (progressive number).
These specifications will also include:
- Drawing of the machine with indication of the individual components to be subject to maintenance (see figure);
- Component description;
- Quantity of components;
- Component class (class A, B or C);
- An eventual document (pdf) which will indicate any cleaning, inspection, lubrication and restoring activities (CILR): these operations can be performed by the operator.
- An eventual document (pdf) which will indicate any other standard maintenance procedures (SMP): these operations can be performed by the operator.
- The type of activity to carry out to complete each maintenance activity (an activity that must be performed by the maintenance technician and not the operator): TBM (Time Based Maintenance, i.e. the operations to be done periodically) or BDM (Breakdown Maintenance, i.e. what to do in case of piece breakage).
- Description of periodic maintenance that must be carried out by the maintenance employee;
- The frequency of the planned maintenance activity (FREQ).
- Duration of the maintenance activity expressed in minutes (T).
- Possible presence of standard maintenance procedures (SMP).
- If maintenance must be carried out when the machine is working or when the machine is stationary (L/F).
Finally, the supplier will have the possibility to attach a pdf containing the CILR (the calendar to carry out the cleaning inspection of lubrication and re-tightening activities). In case of special maintenance, the supplier can integrate the SMP (standard maintenance procedures) and attach a pdf file here as well.
The “Machine Ledger” software system
The management of scheduled maintenance will consist of a time schedule for the use of maintenance technicians.
The maintenance technician will be able to interact with the calendar:
- By recording the maintenance activities completed.
- Signaling the presence of a possible failure, specifying the cause:
- Lack of basic conditions
- Wrong operating conditions
- Insufficient maintenance
- Human error
- Design defect
- External factors
- Write down the minutes used to carry out the maintenance activities scheduled for each day.
- Potential event EWO (Emergency Work Order).
- Have a history of previous activities available. In fact, in the “KPI’s” section, the maintenance technician will be able to take note of the MTBF (Mean Time Between Failures), TBF (Time Between Failure) and MTTR (Mean time to repair) entries in order to obtain breakdown and repair statistics.
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