Integrated Maintenance Planning for Economically Timed Plant Shutdowns
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Solution Overview
Problem
Existing maintenance planning systems for production plants, particularly in the metal production industry, do not necessarily optimize economic operation, as they focus on technical viability rather than economic efficiency.
Innovation Solution
A maintenance planning system that integrates production planning, automation, state monitoring, and business planning systems to determine and optimize maintenance measures based on economic utilization, considering costs, yields, and product quality predictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If maintenance work is scheduled based on technical state evaluation, then the technical viability of maintenance is improved, but the economic efficiency of production plant operation deteriorates
Solution Approach 1:
The patent combines multiple previously separate systems (production planning, automation control, state monitoring, and business planning) into an integrated maintenance planning system. This merging allows the system to simultaneously consider technical maintenance requirements and economic production goals, resolving the contradiction by evaluating both technical viability and economic efficiency within a unified decision-making framework.
Solution Approach 2:
The maintenance planning system is designed to perform multiple functions: it evaluates technical plant states, optimizes maintenance scheduling, predicts future states, and determines economically optimal maintenance timing. This multi-functionality enables the system to address both technical reliability and economic productivity requirements simultaneously, rather than treating them as separate concerns.
2Reliability
If maintenance measures are implemented to ensure technical reliability, then the reliability of production plant is improved, but the productivity of production plant deteriorates due to shutdowns
Solution Approach 1:
The system performs preliminary evaluation of maintenance needs by continuously monitoring the current technical state of the production plant and predicting future states. By identifying maintenance requirements in advance and planning maintenance during optimally timed shutdowns, the system minimizes the impact on productivity while ensuring reliability is maintained through proactive rather than reactive maintenance scheduling.
3Productivity
If production is planned with sufficient lead time to optimize productivity, then the productivity of production plant is improved, but the ability to respond to technical maintenance needs deteriorates
Solution Approach 1:
The maintenance planning system dynamically adjusts maintenance schedules based on real-time technical state evaluations and predictions. Rather than following fixed predetermined schedules, the system continuously adapts maintenance timing to the actual technical condition of the plant, allowing flexible response to maintenance needs while coordinating with production planning to minimize productivity impact.
Data Source
AI summary
A maintenance planning system for a production plant comprises: a production planning system for determining a production sequence for the production plant; an automation system for controlling production in the production plant; a state monitoring system for acquiring states of the production plant and its components; and a business planning system for the economic management of production and maintenance in the production plant. The maintenance planning system is designed for determining maintenance measures for the production plant. When determining the maintenance measures, the maintenance planning system takes into account the information of the production planning system, the automation system, the state monitoring system and the business planning system and performs optimization with regard to an economic utilization of the production plant. The disclosure further relates to a method for determining maintenance measures for a production plant and corresponding computer programs.