The Computerized Maintenance
Management System (CMMS)
A. Proposed CMMS
CAIP,
with assistance from the bus companies, studied the existing diesel bus
operations and maintenance (O&M) organizations and practices to determine
the baseline Egyptian diesel transit bus environment. CAIP then developed a
proposed new organizational structure and reporting relationship for the CNG
bus garages that is designed to enhance the current system, as well as provide
the necessary new equipment and management practices. This effort also includes
development of proposed staffing requirements for maintenance personnel and
management staff.
The new
program is based on CNG transit experience from around the globe, and uses
straightforward requirements to allow efficient implementation into the CTA and
GCBC organizations. Some technologically sophisticated systems are proposed,
but they are being implemented with proper training and provide superior
capabilities for monitoring and ensuring the success of the new CNG programs at
CTA and GCBC. CAIP is assisting the bus companies with developing detailed
management procedures for CNG bus O&M. These include schedules for
inspections; procedures for routine and preventive maintenance; management of
spare parts and supplies; and monitoring, reporting, follow-up, and resolution
of maintenance problems.
B. Need for the CMMS
Currently,
all CTA and GCBC maintenance management activities are performed without the
use of computers. Significant deficiencies exist, including delay in obtaining
spare parts for needed repairs, minimum level of preventive maintenance,
redundancies in maintenance functions, inability to track performance of buses,
and low level of safety checks.
CNG buses
and their support facilities are more sophisticated than their diesel
counterparts. CNG is a gas and leaks are harder to detect than those from diesel.
The fuel tanks that hold the compressed gas are of a high-tech design. The gas
is under high pressure, sometimes exceeding 3,000 PSI. The bus engines and
transmissions are computer-controlled and require complex preventive
maintenance techniques to keep them operating at optimum conditions.
An
enhanced maintenance and safety program is essential for safe and economical
operation of the buses and their support facilities.
C. CMMS Description and Goals
For
sustainability reasons, CAIP is providing the bus companies with a complete
computerized solution for managing and maintaining their new CNG fleets. The
system includes software and hardware packages suited for transit service. The
system allows implementation of modern management practices, emphasizing
preventive rather than corrective maintenance, and includes enhanced quality
control for spare parts, tools, and other resources.
CAIRO AIR IMPROVEMENT PROJECT
CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES 3
The CMMS enables management to:
•
Schedule preventive and predictive maintenance procedures, and parts and labor utilization
for maintenance tasks.
•
Project and monitor downtime and causes.
•
Project and monitor costs, repairs, and
usage of spare parts and labor.
•
Analyze failures, costs, maintenance
procedures, and resource usage.
CMMS usage helps in:
•
Achieving high efficiency in fleet operation (by minimizing failures and
maximizing operating time).
•
Minimizing usage of parts and labor.
•
Maximizing usage of buses and
minimizing downtime.
•
Maximizing buses’ lifetime and
replacement period.
•
Minimizing maintenance and operation
costs.
•
Maximizing profits.
•
Raising performance levels.
The goal
of this project is to establish a fleet computerized maintenance management
system that allows the safe and efficient functioning of a CNG bus fleet for
the CTA and GCBC.
CAIRO AIR IMPROVEMENT PROJECT
4 CMMS DESIGN CONCEPT FOR CNG BUS FACILITIES
SECTION
III. CMMS Description A. Primary CMMS Applications
The following are the major
elements of the CMMS:
A1. Spare Parts Inventory
Inventory
tracking and control is improved resulting in having spare parts when they are
needed and, therefore, ensuring that buses are in service the majority of the
time. Parts requisitioning and ordering is integrated into the CMMS in order to
achieve better ordering efficiency. Vendors and their performance are tracked.
Data from the CMMS is then used to expedite future budgeting and planning
efforts.
A2. Maintenance Scheduling
Preventive
and routine maintenance are especially important for the safe operation of CNG
buses and facilities. Scheduling is optimized for this complicated equipment,
resulting in more efficient operation of both the buses and the support
facilities. Advanced notices of scheduling are issued automatically, resulting
in better planning for manpower utilization. Service contract renewals and
terms are tracked, and early warning of expirations are produced.
A3. Safety Inspections
Visual
and instrumental safety inspections, particularly of the fuel system, are
critical to the safe operation of the buses, fueling facilities, and
maintenance facilities. Computer scheduling of these inspections ensures an
optimum inspection schedule. Furthermore, routine computer analyses of
inspection results warn of impending safety problems.
A4. Fuel and Fluids Tracking
The CMMS
tracks the rate of fuel and fluids consumption on a per-bus basis and/or for
the entire fleet. The system is programmed to automatically warn of excessive
fuel and/or fluids usage,indicating a problem situation. This tracking provides
early warning of a fuel and/or fluids leak,indicating a potentially hazardous
situation.
A5. Performance Monitoring
Tracking
performance of drivers, buses, mechanics, inspectors, and systems through use
of the CMMS leads to improvement in efficiencies and, therefore, cost savings.
Both
on-road
and inmaintenance tracking is performed. Downtime and its causes, costs, repairs,
spare parts’ usage,and labor usage are all tracked. The CMMS is used to
analyze
tracking data, predict future performance, summarize resources expended,
analyze failures, costs, and procedures, and generate reports. Such tracking
and analysis is used in continuous quality improvement.
CAIRO AIR IMPROVEMENT PROJECT
CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES 5
A6. Training
CMMS
outputs are used in training operators, mechanics, inspectors, management
personnel,and other employees. The training schedules are maintained on the
system as well. These uses of the CMMS result in improved efficiency and
better-trained workers, ultimately resulting in cost savings.
A7. Computer-generated Reports
Many
types of reports are generated by the CMMS to support various needs. Both
routine and customized reports can be generated, and queries can be made.
A8. Clearinghouse
Maintaining a clearinghouse of data and information about CNG
is done on the CMMS. Keeping a computerized inventory of books, pamphlets,
service bulletins, CD-ROM’s,
etc.,
allows workers to access needed information easily. The materials and their
usage are tracked, and some of the materials are entered directly into the
CMMS. Sound and readily available information leads to productivity
improvements and safety enhancement.
A9. Transportation Issues
There is
a significant need to track bus and personnel locations on a real-time basis.
There is also a need to analyze current routing and scheduling and make
adjustments, as well as to plan new routes. These functions are easily
performed using the CMMS.
A10. Financial Issues
The
purchasing and inventory control functions interface with the CMMS, resulting
in more efficient operations. Ultimately, these efficiencies lead to cost
reductions.
A11. Interdepartmental
Cooperation
Servicing,
operating, and maintaining a CNG fleet will require a higher level of
interdepartmental cooperation and a need for sharing information. The CMMS
fulfils these needs readily. The technical, procurement, warehouse, human
resources, operation, and workshop functions are all linked.
A12. QA/QC and Auditing
Routine
and non-routine checks of systems, data, personnel behavior, costs, part
failures, and many other items are easily checked by using the CMMS. Solutions,
new approaches, remedial measures, and new designs are all indicated by the results
of computer analyses. Many parts and failures are predicted and, therefore,
preventative measures can be employed. The results of these analyses are a
reduction in costs and the increase in the safety of operations.
CAIRO AIR IMPROVEMENT PROJECT
6 CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES
B. CMMS Design Concept
The CMMS
design concept is based on a revamped maintenance management structure for both
the CTA and GCBC. The existing structure was studied in depth, and the revamped
structure is designed to minimize disruption of the current organization. Annex
A contains details of the revamped structure and highlights where the CMMS will
support and enhance it.
C. CMMS Specifications
C1. General Specifications
The following are the key items
required:
·
Arabic and English
interface.
·
Y2K compliant.
·
Simple user interface.
·
Multiple reports (daily, quarterly,
yearly, and historical).
·
Simplicity of error messages.
·
High security levels.
·
Local technical support.
C2. Hardware Architecture
To
support the CMMS, CAIP offers the following minimum required hardware
specifications for the server and workstations. At each garage, CAIP envisions
one server and approximately 10 workstations, each accompanied by a printer
(see Annex B, Figure B1 for garage computer network).
The server requires: current Pentium technology; 512MB RAM;
50x CD-ROM drive; 1.44MB floppy drive; 20GB internal tape backup; network card;
four 10GB hard disks; 8MB AGP VGA card; two serial, one parallel, and two USB
ports; and a 56k/v90 internal modem.
The
workstations require: current Pentium technology; 128MB RAM; CD-ROM drive;
1.44MB floppy drive; network card; 10GB hard disk; 8MB AGP VGA card; and two
serial, one parallel,and two USB ports.
The
monitors for the server and workstations must be plug-and-play compatible and
require a nominal, 15-inch (13.8-inch viewable) area.
The
network requires a continuous power supply, two hubs (12-port and 8-port) with
transceivers to fiber optic cables, two racks and patch panels matching the
hubs, and a face plate with external box and surface mounting suitable for an
RJ45 connector. CAIRO AIR IMPROVEMENT PROJECT
CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES 7
C3. Software Architecture
The CMMS includes five
interrelated modules as follows:
•
System Control Module;
•
Gate Module;
•
Personnel Module;
•
Inventory Module; and
•
Maintenance Module.
Each of
these modules in the CMMS is designed to support multiple companies,
branches,currencies, languages, and users, as well as featuring security
controls, client/server applications,and the ability to modify screen layouts.
Please refer to Annex B for details and flowcharts showing the relationship and
interconnectivity of the CMMS modules.The System Control Module controls the
other four modules, databases, forms, and the form controls, and can perform
this for multiple companies, branches, departments, and divisions. The system
setup of users and groups, as well as the assigning of security rights to them,
is performed through this module. The operator can also view which users are
active on the system at any time through the System Control Module.
The Gate
Module is the user-level entry into the CMMS, recording employee timesheets,
bus logs, and repair requests.
The
Personnel Module holds the electronic records of all employees, assigning each
a unique identification number, and allows management to route employees to
positions according to skill level and availability, as well as to training
courses as required. The module tracks vacation, sick leave, overtime, days
absent, etc.
The
Inventory Module allows the management to adjust minimum/maximum levels of
inventory, dd, issue, receive, and transfer spare parts, and track stock over
multiple companies, branches,and stores, and do so by item cost or by average
price. The module
is
barcode-enabled and can produce inventory lists by quantity and cost. The
module alerts the operator when inventory is “slow-moving”
or needs to be restocked.
The
Maintenance Management Module records the technical information for maintenance
units,and provides setups for preventive maintenance scheduling, technical and
safety procedures, and required resources.
The
module notifies all other departments related to maintenance with the required
labor skills, materials, and tools needed for each new maintenance operation.
CAIRO AIR IMPROVEMENT PROJECT
8 CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES
SECTION IV. Other Factors
A. Proposed Staffing
The
figures presented in the table below are the estimated staffing requirements
for a garage housing 25 full-size CNG transit buses. The estimates for
transportation and maintenance personnel were based on the number of buses and
the distance they operate
per day.
Staffing requirements for the rest of the garage employees are estimates based on
the CNG team’s experience with facility management in Egypt and
the US. The total
estimated staff for maintaining
and operating the CMMS is two. The Computerized
Maintenance
Management System (CMMS) A. Proposed CMMS
CAIP,
with assistance from the bus companies, studied the existing diesel bus
operations and maintenance (O&M) organizations and practices to determine
the baseline Egyptian diesel transit bus environment.
CAIP then
developed a proposed new organizational structure and reporting relationship
for the CNG bus garages that is designed to enhance the current system, as well
as provide the necessary new equipment and management practices. This effort
also includes development of proposed staffing requirements for maintenance
personnel and management staff.
The new
program is based on CNG transit experience from around the globe, and uses
straightforward requirements to allow efficient implementation into the CTA and
GCBC organizations. Some technologically sophisticated systems are proposed,
but they are being implemented with proper training and provide superior
capabilities for monitoring and ensuring the success of the new CNG programs at
CTA and GCBC. CAIP is assisting the bus companies with developing detailed
management procedures for CNG bus O&M. These include schedules for
inspections; procedures for routine and preventive maintenance; management of
spare parts and supplies; and monitoring, reporting, follow-up, and resolution
of maintenance problems.
B. Need for the CMMS
Currently,
all CTA and GCBC maintenance management activities are performed without the
use of computers. Significant deficiencies exist, including delay in obtaining
spare parts for needed repairs, minimum level of preventive maintenance,
redundancies in maintenance functions, inability to track performance of buses,
and low level of safety checks.
CNG buses
and their support facilities are more sophisticated than their diesel
counterparts. CNG is a gas and leaks are harder to detect than those from
diesel. The fuel tanks that hold the compressed gas are of a high-tech design.
The gas is under high pressure, sometimes exceeding 3,000 PSI. The bus engines
and transmissions are computer-controlled and require complex preventive
maintenance techniques to keep them operating at optimum conditions. An
enhanced maintenance and safety program is essential for safe and economical
operation of the buses and their support facilities.
C. CMMS Description and Goals
For sustainability reasons, CAIP is providing the bus
companies with a complete computerized solution for managing and maintaining
their new CNG fleets. The system includes software and hardware packages suited
for transit service. The system allows implementation of modern management
practices, emphasizing preventive rather than corrective maintenance, and
includes enhanced quality control for spare parts, tools, and other resources.
CAIRO AIR IMPROVEMENT PROJECT
CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES 3
The CMMS enables management to:
•
Schedule preventive and predictive maintenance procedures, and parts and
labor
utilization
for maintenance tasks.
•
Project and monitor downtime and causes.
•
Project and monitor costs, repairs, and
usage of spare parts and labor.
•
Analyze failures, costs, maintenance
procedures, and resource usage.
CMMS usage helps in:
•
Achieving high efficiency in fleet operation (by minimizing failures and
maximizing operating time).
•
Minimizing usage of parts and labor.
•
Maximizing usage of buses and minimizing
downtime.
•
Maximizing buses’ lifetime and
replacement period.
•
Minimizing maintenance and operation
costs.
•
Maximizing profits.
•
Raising performance levels.
The goal
of this project is to establish a fleet computerized maintenance management
system that allows the safe and efficient functioning of a CNG bus fleet for
the CTA and GCBC.
CAIRO AIR IMPROVEMENT PROJECT
4 CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES
SECTION
III. CMMS Description A. Primary CMMS Applications
The following are the major
elements of the CMMS:
A1. Spare Parts Inventory
Inventory
tracking and control is improved resulting in having spare parts when they are
needed and, therefore, ensuring that buses are in service the majority of the
time. Parts requisitioning and ordering is integrated into the CMMS in order to
achieve better ordering efficiency. Vendors and their performance are tracked.
Data from the CMMS is then used to expedite future budgeting and planning
efforts.
A2. Maintenance Scheduling
Preventive
and routine maintenance are especially important for the safe operation of CNG
buses and facilities. Scheduling is optimized for this complicated equipment,
resulting in more efficient operation of both the buses and the support
facilities. Advanced notices of scheduling are issued automatically, resulting
in better planning for manpower utilization. Service contract renewals and
terms are tracked, and early warning of expirations are produced.
A3. Safety Inspections
Visual
and instrumental safety inspections, particularly of the fuel system, are
critical to the safe operation of the buses, fueling facilities, and
maintenance facilities. Computer scheduling of these inspections ensures an
optimum inspection schedule. Furthermore, routine computer analyses of
inspection results warn of impending safety problems.
A4. Fuel and Fluids Tracking
The CMMS
tracks the rate of fuel and fluids consumption on a per-bus basis and/or for
the entire fleet. The system is programmed to automatically warn of excessive
fuel and/or fluids usage,indicating a problem situation. This tracking provides
early warning of a fuel and/or fluids leak,indicating a potentially hazardous
situation.
A5. Performance Monitoring
Tracking
performance of drivers, buses, mechanics, inspectors, and systems through use
of the CMMS leads to improvement in efficiencies and, therefore, cost savings.
Both
on-road
and inmaintenance tracking is performed. Downtime and its causes, costs, repairs,
spare parts’ usage,and labor usage are all tracked. The CMMS is used to
analyze
tracking data, predict future performance, summarize resources expended,
analyze failures, costs, and procedures, and generate reports. Such tracking
and analysis is used in continuous quality improvement.
CAIRO AIR IMPROVEMENT PROJECT
CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES 5
A6. Training
CMMS
outputs are used in training operators, mechanics, inspectors, management
personnel,and other employees. The training schedules are maintained on the
system as well. These uses of the CMMS result in improved efficiency and
better-trained workers, ultimately resulting in cost savings.
A7. Computer-generated Reports
Many
types of reports are generated by the CMMS to support various needs. Both
routine and customized reports can be generated, and queries can be made.
A8. Clearinghouse
Maintaining
a clearinghouse of data and information about CNG is done on the CMMS. Keeping
a computerized inventory of books, pamphlets, service bulletins, CD-ROM’s, etc.,
allows workers to access needed information easily. The materials and their
usage are tracked, and some of the materials are entered directly into the
CMMS. Sound and readily available information leads to productivity
improvements and safety enhancement.
A9. Transportation Issues
There is
a significant need to track bus and personnel locations on a real-time basis.
There is also a need to analyze current routing and scheduling and make
adjustments, as well as to plan new routes. These functions are easily
performed using the CMMS.
A10. Financial Issues
The
purchasing and inventory control functions interface with the CMMS, resulting
in more efficient operations. Ultimately, these efficiencies lead to cost
reductions.
A11. Interdepartmental Cooperation
Servicing, operating, and maintaining a CNG fleet will require
a higher level of interdepartmental cooperation and a need for sharing
information. The CMMS fulfils these needs readily. The technical, procurement,
warehouse, human resources, operation, and workshop functions are all linked.
A12. QA/QC and Auditing
Routine
and non-routine checks of systems, data, personnel behavior, costs, part
failures, and many other items are easily checked by using the CMMS. Solutions,
new approaches, remedial measures, and new designs are all indicated by the
results of computer analyses. Many parts and failures are predicted and,
therefore, preventative measures can be employed. The results of these analyses
are a reduction in costs and the increase in the safety of operations.
CAIRO AIR IMPROVEMENT PROJECT
6 CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES
B. CMMS Design Concept
The CMMS
design concept is based on a revamped maintenance management structure for both
the CTA and GCBC. The existing structure was studied in depth, and the revamped
structure is designed to minimize disruption of the current organization. Annex
A contains details of the revamped structure and highlights where the CMMS will
support and enhance it.
C. CMMS Specifications
C1. General Specifications
The following are the key items
required:
•
Arabic and English interface.
•
Y2K compliant.
•
Simple user interface.
•
Multiple reports (daily, quarterly,
yearly, and historical).
•
Simplicity of error messages.
•
High security levels.
•
Local technical support.
C2. Hardware Architecture
To
support the CMMS, CAIP offers the following minimum required hardware
specifications for the server and workstations. At each garage, CAIP envisions
one server and approximately 10 workstations, each accompanied by a printer
(see Annex B, Figure B1 for garage computer network).
The
server requires: current Pentium technology; 512MB RAM; 50x CD-ROM drive;
1.44MB floppy drive; 20GB internal tape backup; network card; four 10GB hard
disks; 8MB AGP VGA card; two serial, one parallel, and two USB ports; and a
56k/v90 internal modem.
The
workstations require: current Pentium technology; 128MB RAM; CD-ROM drive;
1.44MB floppy drive; network card; 10GB hard disk; 8MB AGP VGA card; and two
serial, one parallel,and two USB ports.
The monitors for the server and workstations must be
plug-and-play compatible and require a nominal, 15-inch (13.8-inch viewable)
area.
The network
requires a continuous power supply, two hubs (12-port and 8-port) with
transceivers to fiber optic cables, two racks and patch panels matching the
hubs, and a face plate with external box and surface mounting suitable for an
RJ45 connector. CAIRO AIR IMPROVEMENT PROJECT
CMMS DESIGN CONCEPT FOR CNG BUS
FACILITIES 7
C3. Software Architecture
The CMMS includes five
interrelated modules as follows:
System Control Module;
Gate Module;
Personnel Module;
Inventory Module; and
Maintenance Module.
Each of
these modules in the CMMS is designed to support multiple companies,
branches,currencies, languages, and users, as well as featuring security
controls, client/server applications,and the ability to modify screen layouts.
Please refer to Annex B for details and flowcharts showing the relationship and
interconnectivity of the CMMS modules.
The
System Control Module controls the other four modules, databases, forms, and
the form controls, and can perform this for multiple companies, branches,
departments, and divisions. The system setup of users and groups, as well as
the assigning of security rights to them, is performed through this module. The
operator can also view which users are active on the system at any time through
the System Control Module.
The Gate
Module is the user-level entry into the CMMS, recording employee timesheets,
bus logs, and repair requests.
The
Personnel Module holds the electronic records of all employees, assigning each
a unique identification number, and allows management to route employees to
positions according to skill level and availability, as well as to training
courses as required. The module tracks vacation, sick leave, overtime, days
absent, etc.
The Inventory Module allows the management to adjust minimum/maximum levels of inventory,add, issue, receive, and transfer spare parts, and track stock over multiple companies, branches,and stores, and do so by item cost or by average price. The module is barcode-enabled and can produce inventory lists by quantity and cost. The module alerts the operator when inventory is “slow-moving” or needs to be restocked.
The
Maintenance Management Module records the technical information for maintenance
units,and provides setups for preventive maintenance scheduling, technical and
safety procedures, and required resources. The module notifies all other
departments related to maintenance with the required labor skills, materials,
and tools needed for each new maintenance operation.
A. Proposed Staffing
The figures presented in the table below are the estimated staffing requirements for a garage housing 25 full-size CNG transit buses. The estimates for transportation and maintenance personnel were based on the number of buses and the distance they operate per day. Staffing requirements for the rest of the garage employees are estimates based on the CNG team’s experience with facility management in Egypt and the US. The total estimated staff for maintaining and operating the CMMS .
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