MonsoonSIM's Maintenance module empowers learners to effectively manage and optimize equipment maintenance, ensuring high performance and reliability in production processes. Let's delve into the key aspects of this module, enabling learners to maintain their assets at their best state:
Machine Degradation:
- Machines within the MonsoonSIM ecosystem degrade proportionally to their usage. This degradation directly impacts production output, emphasizing the importance of proper maintenance practices.
Work Order Execution:
- Maintenance work is executed through work orders, which address the upkeep and repair of machines. These work orders aim to enhance equipment health, performance, and overall production output.
- Production may be impacted when work order is being carried out
Overall Equipment Efficiency (OEE):
- The state of each machine is measured using the concept of Overall Equipment Efficiency (OEE). OEE combines three factors: Availability, Performance, and Quality. A 100% OEE indicates that the machine is operating at its optimal state of health.
Types of Maintenance:
- MonsoonSIM offers two types of maintenance approaches: periodic (preventive) and predictive (conditional) maintenance
- Periodic Maintenance: This type involves performing maintenance work at fixed intervals, regardless of the machine's current health. Each periodic maintenance session incurs a fixed fee and improves the overall health of the asset, consequently enhancing production output.
- Predictive Maintenance: Predictive maintenance relies on physical sensors installed on the assets. These sensors monitor the availability, performance, and quality of the machine. The sensors provide real-time feedback through color codes, indicating the machine's state. Green signifies optimal performance, yellow indicates suboptimal performance, orange implies degradation requiring attention, and red signifies severe problems necessitating immediate maintenance.
- On the day when maintenance work is being carried for your machine, the machine production capacity will be reduced to 50%.
Effective Work Order Management:
- Work orders, encompassing both periodic and predictive maintenance tasks, play a crucial role in asset upkeep. Learners can efficiently manage and execute work orders, ensuring timely maintenance and optimal equipment performance.
Staff Index Impact:
- The effectiveness of maintenance work is influenced by the staff index. Maintaining a staff index of 100% is essential for achieving efficient and productive maintenance operations.
Breakdown Management:
- In the event of a machine breakdown, regular maintenance procedures are insufficient. Major repairs, known as overhauls, are required to restore the machine's functionality. Overhauls demand additional time and resources compared to routine maintenance activities.
- A machine may experience Breakdown if either of the A (Availability), P (Performance), or Q (Quality) index falls below a certain threshold.
MonsoonSIM's Maintenance module equips learners with the tools and insights needed to effectively manage equipment maintenance, maximize productivity, and make informed decisions based on valuable business intelligence.
Note: The complexity of this module is configurable by the facilitator. It is recommended to start with the default configuration and gradually increase the complexity as the facilitator sees fit. This allows for a customizable learning experience tailored to the participants' needs and skill levels.