11 June 2020
The process industry is no exception. CAPEX budgets have been postponed and, as existing equipment can no longer be easily upgraded as it used to be, manufacturers now have to ensure the continuation of the existing equipment. Thus, “operational efficiency” or operational excellence is becoming one of the main drivers of productivity, and significant optimization of the maintenance process is becoming essential to help restore margins.
For the majority of European industries, the maintenance optimization process can be considered as one of the main steps to achieve operational excellence. In the oil, refining, machine building, transport, pharmaceutical and chemical industries, and many other sectors, the costs of intervention and repair of equipment are substantial and therefore have a significant potential for optimization. Moreover, for many European companies, equipment is a key element in the production cycle. Reducing it to a maximum level of productivity has become one of the primary roles of plant management and industrial groups. It is clear that only companies capable of maintaining optimum product quality while using fewer resources will emerge as winners from this crisis, and one of the fundamental conditions for achieving this is the implementation of a well-designed equipment maintenance process.
At the strategic level in the maintenance process, there is a key task for the site manager: finding a balance between the productivity and reliability of the equipment, and its cost of operation. On the one hand, it is possible to use preventive maintenance, which is more reliable but also more expensive than corrective maintenance. On the other hand, it is possible to carry out curative actions to replace and/or repair equipment in case of failure, which is less costly but to the expense of reliability. Therefore, effective repair management requires a combination of several maintenance approaches in this process.
The most relevant approach is the conditional approach, adapted to each class of equipment, taking into account its technical characteristics, criticality, and function. This approach makes it possible to plan maintenance actions according to their actual state, i.e. to control the functioning of the existing asset and, without waiting for a breakdown, to make it evolve.
At the same time, it should be noted that a conditional approach requires an equipment monitoring solution, a global vision on the condition and operation of the equipment, and a tool for assigning and monitoring maintenance interventions. This is where we find the high added value of asset management software, enabling the efficiency of assets and personnel to be improved, such as SIRFULL PowerMaint™ platform.
With a global platform, communicating with various asset-related sources and databases, a content analysis of the indicators can be carried out. This analysis allows the identification of areas for process optimization that need improvement.
With the aim of achieving complete operational excellence, SIRFULL PowerMaint™ platform is based on two main process axes: strategic and applicative. At the strategic level, we define the concept and the basic rules of the global maintenance strategy, “best practices” are identified and the effectiveness of the strategy is monitored and controlled on a global perimeter.
The handling of exceptions is consequently framed and controlled.
Once the maintenance strategy and rules are defined, the question of the application of these rules arises, and an update of maintenance plans and changes to work orders is inevitable.
Today, these types of modifications are made manually in CMMS-type software, with the difficulty of having a harmonized approach, and represent a tedious and time-consuming task. This aspect slows down the improvement of the internal process and represents a significant barrier, both human and financial.
To meet this need, the SIRFULL platform provides a disruptive solution: all modifications to Maintenance Plans can be implemented in mass and automatically. The automation and optimization of the maintenance process start as soon as the Maintenance Plan is established and the change of maintenance rules is simple and fast, with just one click!
In conclusion, while it is clear that the majority of companies have already started to automate the maintenance of their equipment, the majority of them do not pay enough attention to the optimization of maintenance processes, hoping that these functionalities will become available in their existing digital solutions. Unfortunately, standard solutions cannot adapt to everyone at the same time.
The PowerMaint™ Platform can be easily integrated into an existing ecosystem, helping to visualize processes and rebuild the overall maintenance process. It can also, with analytical data, highlight the optimization directions to be taken, and subsequently, make their implementation very simple.
This is why, if we are aiming for complete operational excellence of our industrial sites, the two axes of operation – strategic and applicative – are essential.
Sirfull is a software vendor with a strong industrial culture and French know-how, which develops solutions that enable its customers to anticipate changes in their market.
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Finden Sie an einer Stelle alle Informationen zu Ihrem Schweißbetrieb und verfolgen Sie deren Fortschritt.
Sirfull findet die optimale PQR, die die Parameter der in Ihrem Fall durchzuführenden Schweißung abdeckt, und schreibt aus dieser PQR eine konforme WPS.
Legen Sie die Lage der zu montierenden Schweißnähte und Komponenten Ihrer Ausrüstung auf ihrem Plan aus und exportieren Sie ihn.
Verpassen Sie kein Veröffentlichungsenddatum. Requalifizieren Sie alle 6 Monate die WPQ, fügen Sie das Begleitdokument bei und finden Sie mit einem Klick die Requalifizierungsschweißung in der Montagehistorie des Schweißers.
Find in one place all the information related to your welding projects and follow their progress.
Sirfull finds the optimal PQR covering the parameters of the weld to be performed in your case and writes a compliant WPS based on this PQR.
Locate the welds and components of your equipment to be assembled on its plan and export it.
Don’t miss any validation end date. Requalify every 6 months the WPQR, attach the supporting document and find in one click the requalification weld in the welder’s assembly history.
Retrouvez en un point l’ensemble des informations relatives à vos affaires de soudage et suivez leur avancement.
Sirfull trouve la QMOS optimale couvrant les paramètres de la soudure à réaliser dans votre affaire et rédige un DMOS conforme à partir de cette QMOS.
Disposez l’emplacement des soudures et des composants de votre équipement à assembler sur son plan et exportez-le.
Ne manquez aucune date de fin de validé. Requalifiez tous les 6 mois les QS, attachez la pièce justificative et retrouvez en un clic la soudure de requalification dans l’historique d’assemblage du soudeur.
WELDING SOFTWARE COMPARISON | |||||
FEATURES | SIRFULL | Weldnote | Weldeye | TWI | Weld assistant |
WELDING PREPARATION | |||||
PQR Management | ✓ | ✓ | ✓ | ✓ | ✓ |
Search through qualified PQR and Welder Qualifications approval ranges | ✓ | ✓ | × | ≈ | ≈ |
Automatic Approval Range Calculation | × | ✓ | × | ≈ | × |
Upload your existing PQR documents into the software | ✓ | ✓ | ✓ | × | ✓ |
Code Checking between WPS and PQR to ensure compliance (Warning you of any non-conformance) | ✓ | ✓ | ✓ | ✓ | × |
Automatic generation of WPS | ✓ | ✓ | ✓ | × | ✓ |
WPS translation into a secondary language | ✓ | ✓ | × | × | ✓ |
WPS template customization by user | ✓ | × | × | × | × |
PQR Management and Qualified welder identification in compliance with identified WPS | ✓ | ✓ | ✓ | ✓ | ✓ |
Notifications for welder qualifications that are about to expire | ✓ | ✓ | ✓ | × | ✓ |
Build in technical library of consummables that could be customized | ✓ | ✓ | ✓ | ≈ | ≈ |
Weld mapping on equipment plan (bubbling function) | ✓ | × | × | × | × |
WELDING MANUFACTURING | |||||
Welding project management | ✓ | ≈ | ✓ | ✓ | × |
Filler and materials certificates management | ✓ | ✓ | ✓ | × | × |
Full traceability of weld | ✓ | ✓ | ✓ | ✓ | × |
Weld status management (historization) | ✓ | ≈ | ≈ | ≈ | ≈ |
WPS and Welder performance management (percentage of repairs based on the number of welds completed) | ✓ | ✓ | × | ✓ | × |
Multiple company management | ✓ | ✓ | × | × | × |
User matrix rights | ✓ | ≈ | ≈ | ≈ | ≈ |
Weld sketch designer in the software | ≈ | ✓ | ✓ | ≈ | ≈ |
WELDING NDTs | |||||
NDTs scheduling | ✓ | × | ≈ | ✓ | × |
NDTs report management | ✓ | × | ✓ | × | × |
Automatic initialization of NDT schedules and specific monitoring dashboards | ≈ | × | × | ✓ | × |
NDT report creation | × | × | × | ✓ | × |
WELDING REPORTING | |||||
Welding data book pdf generator / customizable table of content / annexe document importation | ✓ | ≈ | ≈ | ≈ | × |
Manufacuring end report pdf generator / customizable table of content / annexe document importation | ✓ | × | × | ✓ | × |
Welding data book and Manufacuring end report translation into a secondary language | ✓ | ≈ | ≈ | ≈ | × |
Electronic signature | ✓ | × | × | × | × |
Customizable dashboard to follow up on the welding performance indicators such as quality rates, welder performance, non-compliance etc. | ✓ | × | × | × | × |
Weld cost calculation | × | × | × | ✓ | ✓ |
ADDITIONNAL FEATURES | |||||
ERP and/or IT systems integration interface | ✓ | × | ✓ | × | × |
Connection welding source | ✓ | ≈ | ✓ | × | × |
Excel import / export | ✓ | ≈ | ✓ | × | × |
Mass data importation (available with Swift Data additionnal module) | ✓ | × | × | × | × |
User friendly navigation | ✓ | ✓ | ✓ | × | ≈ |