A study on reliability data collection and analysis
Nurminen, Antti (2015)
2015
Konetekniikan koulutusohjelma
Teknisten tieteiden tiedekunta - Faculty of Engineering Sciences
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Hyväksymispäivämäärä
2015-08-10
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201507291466
https://urn.fi/URN:NBN:fi:tty-201507291466
Tiivistelmä
This thesis studied the maintenance data collection process of a container moving vehicle manufacturer, Kalmar. In addition, the data currently collected was analyzed in order to determine its usability for effective RAM analysis.
To understand the data collection process Kalmar’s workshop in Vuosaari harbor, Helsinki Finland was visited and Kalmar reporting manuals explored. The process was found too heavy for effective maintenance reporting. To complete a work report, the system needs at least 100 inputs on the mouse or keyboard. Those inputs are across 35 screens so users spend much of their time moving from one screen to the next.
The Vuosaari workshop reported that after adopting the system called SAP for maintenance reporting the time they spend on reporting has increased by 40 hours per month. It means they have one week less every month to spend on activities other than reporting. This is a huge increase in reporting time even if you take into consideration that during this time their maintenance work has experienced a growth of 25%.
The added time for reporting has not lead to high quality reports. The tools in SAP to input key parameters such as hour counter readings aren’t used, but instead open text fields are used. This is problematic for RAM analysis, because of the difficulty to effectively filter open text information. Thus effective RAM analysis is not viable since work orders have to be opened one at a time to collect the information.
Moreover, the heavy process has led to other practices that decrease the usability of the data. One such practice is to open a single work order per month per machine and then write all the maintenance work done during the month under that same work order. This has the effect of hiding the true amount of failures the machines have experienced – unless the information is extracted by reading work reports one by one.
To improve the usability of SAP, this thesis presents some choices. One approach is to redesign the layouts so only necessary inputs and few screens are needed. However, to achieve this, new software, such as SAP Screen Personas, is needed. Mobile reporting tools could help technicians report to SAP immediately after maintenance is complete or even during maintenance. Moreover, considering that it takes from 8 to 9 days to manage all the reporting activities during a month, the idea of hiring more help to specifically handle the reports should be considered as well.
To understand the data collection process Kalmar’s workshop in Vuosaari harbor, Helsinki Finland was visited and Kalmar reporting manuals explored. The process was found too heavy for effective maintenance reporting. To complete a work report, the system needs at least 100 inputs on the mouse or keyboard. Those inputs are across 35 screens so users spend much of their time moving from one screen to the next.
The Vuosaari workshop reported that after adopting the system called SAP for maintenance reporting the time they spend on reporting has increased by 40 hours per month. It means they have one week less every month to spend on activities other than reporting. This is a huge increase in reporting time even if you take into consideration that during this time their maintenance work has experienced a growth of 25%.
The added time for reporting has not lead to high quality reports. The tools in SAP to input key parameters such as hour counter readings aren’t used, but instead open text fields are used. This is problematic for RAM analysis, because of the difficulty to effectively filter open text information. Thus effective RAM analysis is not viable since work orders have to be opened one at a time to collect the information.
Moreover, the heavy process has led to other practices that decrease the usability of the data. One such practice is to open a single work order per month per machine and then write all the maintenance work done during the month under that same work order. This has the effect of hiding the true amount of failures the machines have experienced – unless the information is extracted by reading work reports one by one.
To improve the usability of SAP, this thesis presents some choices. One approach is to redesign the layouts so only necessary inputs and few screens are needed. However, to achieve this, new software, such as SAP Screen Personas, is needed. Mobile reporting tools could help technicians report to SAP immediately after maintenance is complete or even during maintenance. Moreover, considering that it takes from 8 to 9 days to manage all the reporting activities during a month, the idea of hiring more help to specifically handle the reports should be considered as well.