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Development of plant maintenance management system (pmms): a case study

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2013 IOP Conf. Ser.: Mater. Sci. Eng. 50 012058

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2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 50 (2013) 012058 doi:10.1088/1757-899X/50/1/012058

Development of plant maintenance management system

(pmms): a case study

N A Che Azhar1 and M A Mansor2

1
Faculty of Mechanical Engineering, University Malaysia Pahang, 26600, Pekan,
Pahang, Malaysia
2
Faculty of Technology, University Malaysia Pahang, 26300, Gambang, Pahang,
Malaysia

Abstract. In large plant industry, it is not easy to maintain machine performance without
using any method such as checklist system. Manual checklist is a common maintenance
checklist used in industry. All machine, equipment and parts that need to be checked will be
written down for the employee to do maintenance checks. Converting the manual checklist to
the Plant Maintenance Management System (PMMS) can improve the way of employees work
and make plant management easier. Therefore, a new system was designed to maintain the
equipment so that the activities are more efficient and cost effective. The system consists of
three frames that connect to each other. The frames divide to section, equipment and checklist.
This system also builds to prevent data from arbitrarily changes. Only certain officers or staffs
are permitted to make modifications to data. Using this system, a company can make the
office environment a paperless environment.

1. Introduction
In today's environment, Maintenance Management System (MMS) is wide expands for process plants
to increase profitability by improving reliability and achieving maintenance excellence. Maintenance
is accepted as a means of gaining additional control of operational budgets and significantly increasing
a company’s bottom line. When we consider that maintenance costs can make up 40 to 50% of
operational budgets in capital-intensive industries, the effect of a reduction in maintenance costs is
both obvious and impressive (Daryl Mather, 2002). In addition, maintenance is generally the largest
controllable operating cost of a capital investment industry.
Maintenance can be clarify as activities required or undertaken to conserve as nearly, and as long,
as possible the original condition of an asset or resource while compensating for normal wear and tear.
In the engineering world, the word maintenance can be simplifies as actions necessary for retaining or
restoring a piece of equipment, machine, or system to the specified operable condition to achieve its
maximum useful life. It includes corrective maintenance and preventive maintenance. The objective
of maintenance is to try to maximise the performance of equipment by ensuring that, items of
equipment function regularly and efficiently, by attempting to prevent breakdowns or failures, and by
minimising the losses incurred by breakdowns or failures (C.D. O’Donoghue et al., 2004). In fact, to
maintain or increase the reliability of the operating system taken as a whole is the objective of
maintenance. Properly implemented of an integrated maintenance management can lessen
emergencies by 75%, cut the purchasing by 25%, increase warehouse accuracy by 95% and improve
preventative maintenance by 200%. Then, in the short and long term the potential saving is high if the

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2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 50 (2013) 012058 doi:10.1088/1757-899X/50/1/012058

maintenance cost rising from 9% to 11% per Annum and if maintenance can minimise the costs by as
much as 35% it can count as good management (R. Sivaligam, 1997).
Profitability and competitiveness are the overall goal that a company need. The overall goal can be
defined in different level of control using the term of efficiency, effectiveness and cost-effectiveness.)
The word of efficiency is defined as the ratio of output to inputs of a system and a measure of how
well the system’s output contributes to the business goals and objectives is defined for term
effectiveness (R.N. Anthony, 1998. Collecting all the cost information incurred during equipment life
can be determined as Life Cycle Costing (LCC). The measure of a system in terms of mission
fulfilment and total LCC is defined as cost-effectiveness. The operational maintenance goals and is a
combination of technical and organisational aspects can be relate to high resource efficiency (B. Al-
Najjar, 1997).
New technologies bring us improvement toward job and live. Electronic checklist nowadays can
provide an external memory of pending, completed, and skipped steps. There is no debating it
anymore with a solid foundation in place; electronic checklist processing is growing because it
virtually ensures substantial benefits for any organization that implements it. Computerized
maintenance management systems (CMMS) are one of the ways to improve manual checklist. The
goal of a maintenance manager is to employ a management system that optimizes the use of scarce
resources such as manpower, equipment, material, and funds to maintain the facilities and equipment
that are the responsibility of the maintenance organization. The system should provide for integrated
processes giving the manager control over the maintenance of all facilities and maintainable
equipment from acquisition to disposal.
The facilities maintenance manager with work reception, planning, control, performance,
evaluation and reporting was requirement and assists in modern CMMS nowadays. Besides that, this
system will also maintain historical information for management use. The manager should evaluate
management data requirements and establish electronic data needs prior to acquiring a system or
additions to, or replacement of, an existing system. The evaluation should include a return on
investment (ROI) analysis before investing in additional or new CMMS capabilities. To accomplish
the maintenance organization’s goals, manager should only acquire what is necessary for company.

2. Convert manual checklist to electronic checklist

The development of a system, the main thing that should be implemented is phases of creating new
Plant Maintenance Management System (PMMS). The system design will be develop trough out
many stage before can be running up. The stages of this phase have been planned in developing this
system such as system planning stage, the stage of systems analysis, systems design stage,
implementation stage and the stage of the operation and support system. Things that need to be
addressed in this stage are to understand the problem, determine the existing constraints and finally
identify the benefits derived from the system that will be developed. The problems that have been
detected and gathered will be analyzed and then a plan to solve the problems be created.
The main stage is system design stage. In this stage, the display screen, files and procedures
manual is designed. Then, the design for input data need to be choose for each of available data
whether use button or need to be write. To ensure accurate system, controlled, reliable and easy
maintained this system need to be planned according to the needed of company. When start creates the
system, LAMP (Linux, Apache, MySQL and PHP) will be best software use to complete the PMMS.
Figure 1 at the following page show the step of build up the system.

2
2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 50 (2013) 012058 doi:10.1088/1757-899X/50/1/012058

Start

System Planning Stage

System Analysis Stage

System Design Stage

Implementation Stage

Operation and Support System Stage

End

Figure 1. System development flow.

PMMS was created for one of the largest cement industry in Malaysia. This plant has 7 main
sections consist of crusher, raw mill, core line, coal mill, cement mill, cement silo and packing plant.
This plant also consists of the other section such as blower, palletizer, air and water service and fire
fighting. All of these sections contain 17 to 37 equipments and machines. Each of the equipments and
machines consists 2 to11 parts that need to check every week. Using PMMS can help maintenance
management maintain this plant so that they can run this plant 24 hour per day without having any
problem.

3. Result
Figure 2 at the following page illustrates the main page of the system. Users that want to enter this
system must key in the user data first. The user must enter the staff id, password and section from the
screen. Section consists of mechanical, electrical or production where user must select one of the
sections. User needs to click the ‘login’ button to go to the next screen. User can change their new
password by click ‘change password’ button. The ‘admin’ button design for administration to
modified system such as to update or remove data by a specific person.

3
2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 50 (2013) 012058 doi:10.1088/1757-899X/50/1/012058

Figure 2. Main page.

Figure 3 below shows the front view of the system has been developed. At the top of the screen
display there are several main sections of crusher, raw mill, core line, coal mill, cement mill, cement
silo, packing plant, blower, air & water service, fire fighting and log out. User must click one of the
sections, and then the equipment listed will be reflected at the left side of the web page. By clicking
one of the equipment lists, the checklist list will be reflected to the right side of the web page. Users
just need to click or type the requirement information. All the data collected will store at the data
based then it can be review by the manager as illustrated in figure 4 at the following page.

Figure 3. Maintenance checklist menu

4
2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 50 (2013) 012058 doi:10.1088/1757-899X/50/1/012058

Figure 4. Context diagram

4. Discussion and conclusion

PMMS is convenient, reliable and advantageous to the organization as a whole. Significant time saved
in every level of an organisation which can be utilized for other project, which can bring greater
benefit and productivity. With the implementation of PMMS, need for sorting and filling is fully
eliminated thus saving time and space, which indirectly creates a more conclusive working
environment. Abnormal operating conditions of plant equipment is quickly detected since the data
obtained is immediately and easily uploaded into the database that does not rely on manually data
entry which is time consuming and usually not immediate. Although the initial cost of implementation
might be somewhat higher compared to traditional methods, return of investment (ROI) can be seen as
early as within 1 year to 2 years. The bulk of returns will come from time saved and spent on more
productive projects, significant reduction in the use of paper which in turn result in less cost and
significant reduction in environment impact.

5. Acknowledgements
The authors acknowledge the research grant RDU 120371 received from University Malaysia Pahang.

References
[1] Mather D 2002 CMMS: Journal of a timesaving implementation process
[2] O’Donoghue C D and Prendergast J G 2004 Journal of implementation and benefits of
introducing a computerised maintenance management system into a textile manufacturing
company
[3] Sivaligam R 1997 A12 step programme for moving down the road to recovery, Plant Engineering
Journal of applying best practices to maintenance 51(6) 120
[4] Anthony R N 1998 Management Control Systems, ninth edition, Irwin/McGrawHill, USA
[5] Al-Najjar B 1997 Condition-based maintenance selection and improvement of a cost-effective
vibration-based policy for rolling element bearings, PhD thesis, Lund University,
Department of Industrial Engineering.