It is carried out on the basis of a prediction derived from the analysis and evaluation of significant parameters that describe the level of degradation of an object.

Analytical and statistical methods

The predictive maintenance module includes a statistical calculation method based on Weibull analysis. The maintenance management system will calculate the parameters of the Weibull probability distribution and the algorithm will calculate the optimal interval for timely maintenance before malfunction occurs.

Not only that the calculation emphasizes the financial aspect; i.e. the lowest cost of performing the maintenance itself is taken into account (post-malfunction maintenance expenditure vs. preventive maintenance as well as the cost of human resources, materials, etc.). A record of historical data of maintenance performed on the object under consideration is used for the calculation which provides a reliable basis for a realistic result of a properly timed maintenance schedule. Manual data input can also be used for the calculation, where different cost change behaviours can be simulated.

MES PATRIOT – the information system for production

A system that brings order to production and saves costs and time

For more than 25 years, dataPartner has been developing the MES Patriot production information system, helping manufacturing companies gain a competitive advantage, improve labor management, achieve savings and find spare capacity. Production tracking enables real-time monitoring of key production parameters. Working with online production data allows you to use modern technologies for problem analysis and rapid response, monitor and “see online” production, identify savings in production and do production better, more efficiently and faster. MES Patriot monitors process parameters, tracks purchased parts, controls the production process and evaluates process errors.

This is preventive maintenance according to technical condition, based on data obtained by monitoring performance and/or parameters.

Operational data usage

The PATRIOT® 3.0 maintenance management system enables the automatic collection and evaluation of operational data of maintained equipment. It includes a SCADA system optionally supplemented with diagnostics even for dislocated sites. Most often, information from production control systems can be used directly for this purpose and if data is not available standard sensing units can be connected. The sensed operational data is stored in a database where it is used for analytical methods of time-to-malfunction calculations in predictive maintenance. In case of difficulties in implementing the SCADA system its operation can be replaced by batch data from the on-site diagnostics with off-line transmission of the measured data to the maintenance management system.

Operational data or data from diagnostic system records are used to predict future conditions and events. Based on these data; calculations of key performance indicators (KPIs) are performed to quantify the overall performance. The technical KPIs that are measured include MTBF, MTTR and the reliability and availability indicators OEE and TEEP. The operational data is also used to predict the lifespan of machines, groups and individual components. They are also used as input information for spare parts inventory management.

This is a periodic (scheduled) maintenance with predetermined intervals or number of attained cycles. It is carried out in a planned manner without prior determination of the actual condition of the object. It is a preventive measure aimed at extending the service lifespan, minimising downtime, and ensuring the operational and safe condition of machinery, equipment and other assets. It includes inspections, cleaning, lubrication, calibration, etc. If periodic maintenance is carried out correctly and effectively it should reduce breakdowns and failures, i.e. corrective maintenance.

An optional add-on module is available in the Patriot® 3.0 maintenance management information system:

Maintenance plan optimization

A very useful feature is the optimization of the periodic preventive maintenance schedule. There is a functionality that organizes the maintenance schedule according to the individual maintenance objects (both planned and operational maintenance - corrective, post-malfunction). This plan is generated automatically according to limit conditions; the key is the possibility of manual "fine-tuning" according to the actual needs of the available resources. The plan is focused on maintenance of objects with an emphasis on making them operational as quickly and efficiently as possible.

Maintenance management system PATRIOT® 3.0 supports the restoration of objects using all maintenance strategies - Corrective, Preventive, Diagnostic und Predictive maintenance.Maintenance is a valuable instrument of MES

The Patriot® 3.0 maintenance management information system belongs to the group of systems known as CMMS (Computerized Maintenance Management Systems) or EAMS (Enterprise Asset Management Systems). With its help comes an endless possibility to manage the maintenance of both production and non-production assets, technological units and individual machines. The system can also be used to manage the maintenance of buildings and their parts. Within the MES, the maintenance management system can coordinate downtime with production schedules and predict the time of failure of production equipment. This contributes to increased utilisation of production assets at optimum maintenance costs and high reliability.

The PATRIOT® 3.0 maintenance management information system is modular:

• The basic set of necessary functionalities includes
  • Maintenance object register (description of technical locations, equipment criticality, hierarchy)
  • Human resources list (directory of people including skills and course tracking)
  • Technical documentation of machinery and equipment (electronic archiving)
  • Maintenance kiosks (screens for maintenance staff to work with the system)
  • Maintenance requirements (work orders, work reports)
  • Reports (graphs and outputs of maintenance activities)
  • Checklists, job descriptions, missed deadlines (summary report)
  • Documentation management (documentation and attachments in digital form, electronic archiving)
  • Layout of maintenance sites (map with marked maintenance objects in failure)
  • Notification, escalation (monitoring of maintenance requirements)
  • Cost tracking

• Optional additional modules:
  • Maintenance scheduling (event calendar)
  • Resource planning (personnel, material and ND, tools, production time, finance, external resources)
  • Spare parts inventory and inventory management
  • Collection of operational data, monitoring of technical status (SCADA category)
  • Operational reliability of critical equipment (using Weibull analysis)
  • Predictive maintenance and preventive maintenance optimization
  • Maintenance planning and scheduling based on OEE and other maintenance performance indicators
  • General integration module with ERP system
  • Mobile apps for phones and tablets (diagnostic data collection, reporting of maintenance activities, access to documentation)
  • Augmented reality data visualisation

Benefits of using the PATRIOT Maintenance Management information system

It minimizes the number of unplanned downtimes and thus increases the reliability of production, can significantly extend the service lifespan of production equipment and thus increase the economy of production. It optimises the deadlines for the execution of planned maintenance tasks contributing to the reduction of operating costs. This contributes to higher utilisation of production assets at optimum maintenance costs and to maintaining high reliability.

Reports on maintenance activities are also a very viable tool. The reports can quickly and clearly evaluate the current state of maintenance from multiple perspectives; the frequency of failures in individual equipment or production units based on historical and current data. Reports can be selected from a set of proven and frequently required reports or can be individually prepared. Virtually every report provides the option to customize and save filters that allow further customization of the view of the required data.

Correct terminology and an ergonomic and intuitive user interface play a very important role. The terminology is in line with EN 13306 (010660) ed. 2: Maintenance - Maintenance Terminology which unifies terms and facilitates communication across the maintenance and asset management community. The ergonomic and intuitive user interface is designed in a unified spirit and allows for easy and intuitive operation at the level from the maintenance terminal screens to the planning forms. The user interfaces also include mobile devices, smartphones and tablets which provide a working environment consistent with the entire system. This fact significantly contributes to the ease of implementation of PATRIOT® 3.0 by end customers and its smooth acceptance by all employees.