Total productive maintenance method and software for cement industry

Abstract

This invention involves a total productive maintenance software for monitoring the processes of production lines in the cement industry which functions as a management dashboard for overlooking the equipment and staff. The system is programmed via MS Excel using functions and macros and formula writing, so it is adaptable to the variety of systems in factories. It collects data and uses methods such as OEE, 5S and PM in order to perform data analysis, troubleshooting, leak detection and preventive maintenance.

Description

Total Productive Maintenance Method and Software for Cement Industry

[0001] The innovative total productive maintenance software that has been developed for monitoring production lines within the cement industry is poised to revolutionize the way in which factories operate. Functioning as a management dashboard, this software provides a comprehensive overview of equipment and staff performance. One of the key features of this software is its adaptability to a wide range of systems within cement factories. Programmed using MS Excel, the software utilizes functions, macros, and formula writing to create a dynamic platform that can be customized to meet the unique needs of any production line. This adaptability ensures that the software can seamlessly integrate into existing factory operations, providing a seamless transition towards improved monitoring and maintenance practices.

[0002] In terms of functionality, the software excels in data collection and analysis, using methods such as Overall Equipment Efficiency (OEE), 5S, and Preventive Maintenance (PM) to identify areas for improvement and optimization. By analyzing key performance indicators and conducting thorough troubleshooting, the software can pinpoint issues such as leaks or inefficiencies in the production process, enabling factory managers to take proactive measures to address these issues before they escalate.

[0003] Overall, this total productive maintenance software is offering a sophisticated solution for monitoring and managing production processes. With its advanced capabilities and user-friendly interface, this software is set to empower factories with the tools they need to ensure optimal performance and efficiency.

[0004] G06F17 / 60 – G06Q50 / 08

[0005] CN115630714

[0006] INTELLIGENT PRODUCTION LINE TPM SYSTEM

[0007] The invention relates to an intelligent production line TPM system, and the system comprises an equipment repair module which is used for carrying out the manual repair or automatic repair of equipment; the spot inspection task module is used for performing task triggering on the equipment needing regular spot inspection, judging whether the spot inspection is delayed or not according to regular spot inspection time, and performing spot inspection or maintenance on the equipment which does not need the delayed spot inspection after passing through a person; the regular maintenance module is used for performing task triggering on the equipment needing regular maintenance, judging whether the maintenance is delayed or not according to requirements, and maintaining or repairing the equipment which does not need the delayed maintenance after confirmation; and the equipment maintenance module is used for carrying out maintenance on the maintenance tasks sent by the equipment repair module, the point inspection task module and the regular maintenance module according to the maintenance strategy. According to the device, efficient equipment management, point inspection and maintenance of the TPM function system can be realized.

[0008] The mentioned invention relates to a TPM maintenance system which is similar to the claimed solution in overall function, however, this system is automated and requires several modules while ours employs methods that can be conveniently adapted by any production line, manual or automated.

[0009] CN1559772

[0010] CEMENT PRODUCTION MONITORING SYSTEM

[0011] A monitor system for managing and controlling the production line of cement is composed of a raw materials proportioning control system connected with Ethernet and a network management system. Said raw materials proportioning control system consists of several subsystems for acquiring and maintaining the needed in-situ data and controlling relative equipment. Said network management system can process said data in order to inquire and regulate them by managers. The regulated technological parameters are transmitted via network to said control system for updating the management.

[0012] Similar to our claimed patent, this system involves cement production monitoring, but the comonants and methods are completely different. For instance, our system operates based on TPM and applies to any production line, whereas this one requires certain devices connected via Ethernet.

[0013] CN104715311

[0014] EQUIPMENT MAINTENANCE MANAGEMENT SYSTEM OPERATION OPTIMIZING METHOD

[0015] The invention is applicable to an equipment maintenance management system, and provides a systematic, normalized and standardized equipment maintenance management system operation optimizing method (SOOM) which can execute self optimization on the operation process of each subsystem of the equipment maintenance system, interactive optimization on each subsystem, and integrated optimization on the general equipment maintenance management system. Firstly, each subsystem consults Plan-Do-Check-Act (P-D-C-A) for self optimization respectively, and what is critical is that regulations which accord with conditions of each factory and are simple and clear are make for each execution point; secondly, the principle for interaction of each subsystem is made, for example, when a condition X happens in the case of BD operation, a BDA system is switched instantly, and when a condition Y happens, a PMP system is switched instantly; then, each execution person only needs to operate each subsystem according to the regulations and execute each interaction effect, and thus, a normalized self optimization and interactive optimization system is formed; and finally, sustainable optimizing development for the enterprise equipment management system is achieved. According to different development levels of the enterprise equipment management, the SOOM can be derived as a three-level, a four-level, a five-level, a six-level or multilevel system execution optimizing method, and can be expanded to be applied to other operating systems.

[0016] This patent proposes a equipment maintenance management system which is applicable to all factories, therefore its function is very similar to our claimed system. However, this one uses SOOM and PDCA methods whereas ours uses OEE, TLR, the 5S and PM.

[0017] CN116882561

[0018] CEMENT PRODUCTION AND OPERATION PREDICTION ANALYSIS METHOD

[0019] The invention discloses a cement production and operation prediction analysis method, which belongs to the field of production analysis system software, and comprises the following steps of: (1) selling on the basis of production, inputting a prediction time period, a product output ratio, a design yield, a production line plan and production line state equivalence by a user through a prototype interface I, and automatically generating a prediction yield by clicking calculation, such as annual, quarterly and monthly calculation; if yes, the yield of the corresponding month can be produced; (2) production is determined by sales, a user inputs a prediction time period, a design yield, a product plan sales volume, a production line plan and a production line state equivalent value through a prototype interface 2, the number of days of production halt, production limit and total production and the number of days required by prediction production can be automatically generated through click calculation, such as annual, quarterly and monthly calculation, and the number of days required by production of corresponding months can be output.

[0020] This patent involves a a cement production and operation prediction analysis method that shares some qualities with our claimed system, for instance they both rely on input data and run calculations and analysis to improve the cement production line. However, ours is more adaptable and could be used by any production line, and focuses on optimizing efficiency of equipment while this one emphasizes sales prediction.

[0021] CN101776904

[0022] METHOD FOR MONITORING CEMENT PRODUCTION IN COMPUTER LOCAL AREA NETWORK

[0023] The invention relates to a method for monitoring cement production in a computer local area network, belonging to the technical field of cement production. In the invention, a computer hardware and a cement production software control system. The invention is characterized in that the cement production software control system is connected with a local area network data server by a network, and transmits operating state and technique parameters of cement production equipment to the local area network data server; and the local area network data server is connected with a monitoring terminal computer by a local area network. The method has the advantages of having simple structure, reliable performance, stable operation, low cost, convenient monitoring, accurate data, preventing virus from invading, having high automatic level, knowing and controlling the production process in real time, and improving the yield and quality of products and the like.

[0024] This invention, similar to our proposed system, offers a method of monitoring cement production lines, but it emphasizes operating within LAN to limit virus attacks and displays a real time simulation, while ours is primarily about performing preventive maintenance and optimizing equipment efficiency based on data entry.

[0025] The invention described is a total productive maintenance software designed for managing production lines in the cement industry. It functions as a management dashboard overseeing equipment and staff. Programmed in MS Excel using functions, macros, and formulas, its design allows for customization according to specific factory strategies. The software includes sections on schematic factory view, user interface, OEE, data collection, data analysis, troubleshooting, leak detection, organization, and preventive maintenance.

[0026] The software consists of three main sheets. The first sheet presents a schematic view of the factory with icons representing various aspects of the software and input data for operations and energy dashboard. The second sheet focuses on equipment details such as operating hours, electricity consumption, and production tonnage. The third sheet features an OEE dashboard showing equipment effectiveness and waste analysis.

[0027] OEE calculation involves collecting data on shifts, stops, capacity, and defects, then processing this information to determine availability, performance, and quality losses for each machine. The TLR sheet tracks energy consumption and budget plan deviations using IF formulas. Data analysis integrates energy, OEE, and production statistics to align with budget plans. Troubleshooting sheet analyzes production breaks and suggests solutions. Leak detection sheet identifies leakage points and measures gas values to calculate and display leakage amounts.

[0028] The 5S organization method and preventive maintenance program are included, specifying equipment locations, maintenance tasks, and reporting requirements for operators. Formulas are used to flag discrepancies or inconsistencies in maintenance operations. Overall, the software provides a comprehensive solution for efficient maintenance and management of cement production processes.

[0029] Many industrial organizations from a wide range have embraced Total Productive Maintenance (TPM) to enhance productivity and system output, driven by global competition and the need to boost manufacturing and production line efficiency. Current methods of management and maintenance in construction related industries, and more specifically the cement industry could benefit greatly from implementing TPM modules. Considering there are no widely used programs in these production lines that can offer economic insights by observing the equipment and productivity in the past, evaluating the present situation and devising the most effective plan for the future. In the absence of such a system, management teams tend to make decisions based on experience and reports of the experts, which can lead to irreparable mishaps and losses. Therefore, a software that would create a logical and healthy relationship between operators and machinery by means of data analysis can be of immense help. The proposed patent addresses this need and employs effective problem solving to boost productivity, safety and health in the workplace while preventing breakdowns and accidents.Solution of Problem

[0030] The claimed invention is one of the few total productive maintenance softwares for management and control of all processes and production lines in the cement industry which functions as a management dashboard for overlooking the equipment and staff. It is programmed via MS Excel using functions and macros and formula writing. The reason that Excel was used for the software design is because factories have different strategies based on the type of product and the number of production lines, so their demands vary according to the relevant parameters. Nevertheles, the proposed design and formulas are the same and can be adjusted accordingly to contain sections such as schematic view of the factory, user interface, OEE, data collection, information processing unit, TLR, data analysis, troubleshooting, leak detection, organization and preventive maintenance methods.

[0031] The first three parts involve basic information about the production line. Sheet 1 is a schematic of the factory view and is designed using shapes, wherein you create an entry and connect it to sheet 2 by hyperlink. On this page, the various icons that appear on the interface are designed through shapes and carry information about the software, the designer's information and history. They also include an entry for input data for the operation, the use of the software and the energy dashboard of the production line based on the number of active lines.

[0032] To start, using the shapes tool, the production path from the beginning to the end as well as the existing equipment is designed. Then for each equipment these icons are defined: hr (hours of operation) - kwh (electricity consumed) - ton (production tonnage) - kwh / hr (how many kilowatts of electricity consumed every hour) - kwh / ton (how many tons of production per kilowatt hour). For the calculation of operating hours, electricity consumption, and production tonnage, data input information link is pasted. In order to calculate the icons of how many kilowatts and how many tons per hour are consumed or produced, kwh is devided by hr and ton. To check the correct operation of the equipment on click on each icon and put formula 1 or formula 2 from the home-conditional formatting-new rules manager toolbar and choose green or red color. In the energy saving evaluation table from the data input, the relevant information received by the laboratory unit is converted to percentage, relative to the determined index and importance level, and placed in the table.

[0033] The third sheet is dedicated to the OEE dashboard to show overall equipment effectiveness. For each device in the OEE method, the graphs section is hyperlinked, and to calculate kwh / ton, lit, kcal / kg, T / H, Nm^3, SEC, m^3 / ton, kwh / ton, the links are pasted from the relevant sheet. The equipment control dashboard is hyperlinked from the sheet related to OEE to the energy dashboard. After preparing the energy dashboard, the number of production lines is put through the dashboard. The primary function of the OEE tool is identifying the waste related to the equipment in different departments and carrying out solutions in order to eliminate the waste and utilize the equipment to full capacity.

[0034] Furthermore, the purpose of OEE is to analyze, report, and determine the standard path to improve the effectiveness of the equipment by eliminating large wastes. Determining OEE has many benefits for operators, shift managers or line managers. In the TPM approach, it is used by operators to collect daily information about the equipment to run calculations. The collected data gives the operators more knowledge about the equipment, shifts the attention of the operators onto the waste and fosters a sense of ownership in them.

[0035] OEE calculation is done according to multiple factors in two steps; a form must be designed for each step. These steps are:

[0036] A- Data Collection sheet: Collecting information on the shift length (in minutes), partial stops (in minutes), breaks (in minutes), general stops (in minutes), nominal capacity (numbers per minute), total goods and defects number.

[0037] B - Information processing sheet: the information collected by the above form for each of the machines or equipment must be calculated based on three other required indicators, which are respectively: Planned production time (in minutes), Duration of actual operation (in minutes) Good count (in number). Based on the A and b variables availability, performance and quality loss can be calculated.

[0038] On the TLR sheet, we put information regarding calculations of electric and thermal energy consumption, production and any element that needs to be considered in the budget plan. To calculate any deviation from the original budget plan, for which we use IF formula 1 and 2. On the evaluation and sheet, first the assessment of different departments in order to save energy, and second, the performance of the units in the departments, are measured by determining the parameters, index and importance factor and converting it into a percentage of formula 10.

[0039] The Data Analysis sheet involves analyzing the data on electrical and thermal energy, OEE, production statistics and any available primary data are put together, and the past and current information is made into a chart and is aligned with the budget plan. The result will show any specified variations and the plans can be determined.

[0040] The Troubleshooting sheet is created based on data concerning any breaks in production with descriptions on time and number of repetitions. After this data is gathered from the operators or operator's control room, it is sorted into a table, and separated in accordance with the related unit. Then it is compared to the same data from last month via a comparison matrix. Ultimately, depending on the importance of the type of break in the production cycle and the resulting loss, the next course of action to solve the issue is decided.

[0041] Leak detection sheet makes it possible to find and identify the amount of leakage. First the points where the production unit performs tapping technique in the production line are determined. Then, an isometric and schematic map is prepared, and the location of the measurement points are marked. Next, the values %CO2,T(°c) %o2 p(mbar) is measured and specified along with the information of the baking oven and fuel type. Afterwards, a line is drawn in the flow chart and schematic plan where the subtraction of the beginning and end of each point will conclude the exact amount of leakage between the two points and can be displayed as a diagram.

[0042] Lastly, the 5S method of organization and PM aka preventive maintenance program are included in a sheet. In this sheet, all the equipment along with their locations are specified and sorted into tables. Additionally, the operations that must be done for the maintenance and repairs are specified, using information from the local operators, who are required to comply and complete the report sheet. In case of any discrepancy or inconsistency of the alarms, conditions will be set in formulas 1 and 2.Advantage Effects of the Invention

[0043] Improved workplace safety

[0044] Enhanced product quality

[0045] Improved overall equipment effectiveness

[0046] Increased customer satisfaction

[0047] Higher equipment utilization

[0048] Reduced cost of production

[0049] Practical waste management

[0050] Product delivery without defects

[0051] Uptimal hygiene and discipline

[0052] Preventive maintenance and leakage detection

[0053] Shows a general flowchart of the system's process.

[0054] Displays a flowchart of the Total Productive Maintenance system's function and process. After the software design has been adjusted to the production line's demands and priorities, the data regarding the timing of the process, state of the equipment and the production is entered by the user in real time. This data may include the operating shifts, breaks or stops in the process, any breakdowns or malfunctions, the number of defects and production yield. Additionally any data regarding thermal or electrical energy consumption enters the the management dashboard. Once all the necessary data is collected, OEE calculations are performed based on data processing formulas. Then any budget deviations and overall planning is calculated via TLR. Leak detection and troubleshooting is performed based on the data analysis section so that the best course of action is decided for maximum efficiency. In order to organize the process of production the 5S method including Sort, Set in Order, Shine, Standardize and Sustain. The Preventive Maintenance method is employed to keep the equipment in their most efficient state at all times.Examples

[0055] The patent includes a TPM software for cement production and acts as a management dashboard which can be designed according to the features of any production design using MS Excel. After customizing the formulas and developing the interface, the users enter the necessary data about the on the shift length, partial stops, breaks, general stops, nominal capacity, total goods and defects number. In addition to that, any data regarding each piece of quipment's energy consumption, leakage or waste is entered in the relevant sheets. Then, methods such as OEE use this data and run calculations on availability, performance and quality loss.

[0056] Then, electrical and thermal energy data, OEE, production statistics and any available primary data are put together, and the past and current information is made into a chart and is aligned with the budget plan in the data analysis section. In case of accidents, the leak detection and troubleshooting segment will help identify the source as quickly as possible and decide on the best course of action based on prior data. With the help of 5S and PM technique, the data gathering process is organized in a functional manner so tha preventive maintenance measures can be taken accordingly.

[0057] The following are the formulas mentioned in the solution that can be customized to suit the specific needs of the production line process:

[0058] 1: (=IF(cell address>=standard value;TRUE;FALSE)) color selection)

[0059] 2: (=IF(cell address<standard value;TRUE;FALSE)) color selection)

[0060] 3: H=A-(B+C)

[0061] 4: I=H-D

[0062] 5: J=F-G

[0063] 6: access level 100%* (I / H)

[0064] 7: 100% performance * ((F / I)-E)

[0065] 8: 100% quality* (J / F)

[0066] 9: OEE = quality % * performance % * access level %

[0067] 10: Importance factor + ((initial data amount - index amount) / index amount * 100)

[0068] This invention may be of immense help in any production line, in the cement industry or others, that lacks the necessary organization and maintenance systems. More particularly, It can be used in any factory which operate using heavy machinery and prefers cost-effective, accessible methods to boost productivity and control waste.

Claims

A Total Productive Maintenance software for monitoring the processes of production lines in the cement industry which functions as a management dashboard for overlooking the equipment and staff.According to claim 1, the software is programmed via MS Excel using functions and macros and formula writing, so it is adaptable to the specific systems in each factory.According to claim 2, the software features a user interface for data input regarding each piece of equipment's hours of operation, energy consumption and production tonnage in proportion with each other.According to claim 3, the software utilizes Overall Equipment Efficiency (OEE), TLR, the 5S and PM methods to perform data processing and analysis, organization, leak detection,waste control, budget planning, troubleshooting and preventive maintenance.

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