Maintenance and Repair Management
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Biltaş Maintenance and Repair Solutions
Fully integrated with ERP systems.
Reduce your company’s maintenance costs by 80% with BSOFT Maintenance!
- Increases plant lifetime.
- Ensures production continuity.
- Easy installation and commissioning in a short time.
- Periodic Maintenance
- Predictive Maintenance
- Incidental Maintenance
- Work orders
BSOFT Maintenance is a modern Maintenance and Repair software that performs maintenance operations of your business’s machinery, buildings, equipment, etc. equipment.
The Importance of Modern Maintenance Systems
Incidental shutdowns or under-capacity operation of machines and facilities cause significant losses. Modern maintenance systems developed with the aim of achieving zero error, zero accident, zero downtime and minimum losses are gaining importance.
Nowadays, businesses make large investments in equipment/machinery and hardware and they want to get a return on these investments. For this purpose, by using new maintenance methods, they aim to minimize technical problems with planned maintenance, increase the efficiency of the production process and prevent the effects that increase costs.
Objectives of Maintenance Activities
and New Methods
Maintenance is a set of activities carried out to maintain the functions of equipment and systems in operation at the highest performance. Maintenance activities should be directed towards four main objectives:
- Reducing the cost of production
- Contributing to product quality
- Increasing plant lifetime
- Ensuring continuity of production
With the New Maintenance Methods, it is ensured that labor and spare parts requirements are calculated before periodic maintenance, maintenance work orders are created automatically, work orders are followed up, and labor and spare parts used in the maintenance process are entered into the system. Thus, inventory costs are reduced and bottlenecks are prevented.
Modern Maintenance Management and BSOFT Maintenance
The aim of New Maintenance Management is to ensure the longest life, least cost and failure-free use of fixtures. It aims to minimize problems and increase the efficiency of the production process in companies that carry out uninterrupted production.
BSOFT Maintenance is a modern Windows-based Maintenance and Repair Management System application designed to support modern maintenance methods, developed with today’s technologies, consisting of many modules that work integrated with each other.
Maintenance and Repair Management System
BSOFT Maintenance is a system that prepares periodic maintenance plans of equipment such as machinery, buildings, equipment of enterprises (production or service), and tracks maintenance and repairs, labor, material consumption, external maintenance expenses, failure statistics on the basis of work orders.
It consists of many modules and sub-modules that support maintenance types such as breakdowns, maintenance performed outside the company, and work integrated with each other. It is a modern application software based on Windows and developed with C# (.net).
Benefits and Features
- Ensures that maintenance works are carried out in a timely and economical manner,
- It ensures that all failures are recorded and the financial burden of each failure is monitored,
- Thanks to the periodic maintenance model, it ensures that the planned maintenance of each machine is kept under control and machine life is increased,
- Thanks to the periodic maintenance model, it enables the necessary labor and spare parts needs to be determined in advance,
- Thanks to the periodic maintenance model, it enables planners to make healthier production plans,
- Thanks to the predictive maintenance model, it ensures that measurement values are entered for each machine and automatic maintenance instructions are given within the specified tolerance range, thus protecting the machines from possible failures,
- Provides maintenance costs (labor and material) on machine group, machine and work order basis,
- Thanks to Safety and Work Instructions, it reduces the possibility of making mistakes, increases labor productivity and creates a “KNOWLEDGE BANK” related to the maintenance of the enterprise,
- Ensures that the performance of maintenance personnel is monitored,
- Since maintenance histories are kept, it enables reporting of maintenance statistics and machine lifetimes,
- Thanks to the warning system, it provides effective notification of information on Production Affecting Breakdowns, Open Breakdown Work Orders, Open Planned Maintenance Work Orders, Pending Work Requests, Expired Maintenance, Expiring Maintenance and Critical Stock Levels,
- It allows you to get an unlimited number of graphical reports (maximums, downtimes, breakdowns, etc.).
Periodic Maintenance
Considering the past performance of the equipment/machinery, the operating conditions and the experience of the maintenance team, the time intervals at which each equipment/machinery should be stopped and serviced are carefully planned. This process is called periodic preventive maintenance, and with this method, more than one maintenance recipe can be made for each equipment/machine to be maintained. This method is the most widely used maintenance approach in the industry and usually yields the most effective results.
In this audit-based maintenance process, the parts to be replaced in the machine are determined in detail and these parts are kept in stock to avoid any delays in the maintenance process. In this way, the efficiency and lifespan of the equipment is increased, while possible breakdowns are prevented and the production process is ensured to continue without interruption. This planning and inventory management contributes to more efficient and effective maintenance processes.
Predictive Maintenance
Predictive maintenance is the measurement and comparison of selected parameters with predetermined limit values using graphical trends in order to detect, analyze and correct malfunctions in machinery and equipment before they become problematic. In other words, it is maintenance based on machine performance. In other words, Predictive Maintenance technique detects malfunctioning early, ensures that it can be corrected in planned downtime, cheaper and in a shorter time without any maintenance delays. The approach used is to predict the future state of machinery and equipment by monitoring their current and past conditions.
The main principle here is to monitor the performance of the machines with measurements made during production and to decide when maintenance is required, to interrupt production for a short period of time and to repair the previously determined malfunction. Within the framework of the program made by taking into account the character and working conditions of the machine, some parameters are checked and measured without stopping production. After the fault is diagnosed, the necessary spare parts are provided, production is stopped, maintenance is carried out in the shortest possible time and production is resumed.
Incidental Maintenance
It includes maintenance and repairs when the equipment/machine stops due to an unexpected malfunction. In other words, it is the maintenance performed when the malfunction occurs. In general, this maintenance method can be applied in plants and workshops that produce with machines that have many spares and are not too expensive.
However, the main disadvantage of this maintenance method is that it is very difficult to make a real production plan, as it is not known when damage will occur.
Incidental Maintenance General Features
- Installation Options: BSOFT Maintenance can optionally be installed on server or PC (Client). The database is always located on the server and no information is stored on the client side.
- User Authorization: In BSOFT Maintenance, all users log in with their own passwords and perform operations according to their usage authorization. Authorization levels:
- Full authorization
- Report faults and view related records and reports
- Manager authorizations (such as viewing all reports, prioritizing failures)
- Quality Management Compliance: The forms, lists, cards, reports and instructions used in BSOFT Maintenance are compatible with quality management systems such as ISO 9000, ISO 14000, OHSAS 18000, TPM 5S and Six Sigma.
- Reporting Capability: In addition to the hundreds of reports it contains, BSOFTCare has a reporting program that allows users to prepare their own reports and add them to the system. With its filtering structure, different analyzes and graphs can be easily accessed.
- Log System: All system operations (additions, changes, deletions) are logged in detail and can be easily reported.
- File Conversion Feature: Reports can be converted to different document formats such as word, excel, pdf, html, mht and rtf.
Back Office Integration
BSOFT Maintenance has integration with many commercial and ERP applications available in the market, primarily BSOFTerp . Businesses that want to use BSOFTBack Office outside of the existing application structure can use their own Back Office software that is fully integrated with BSOFTBack Office.
Fully Integrated Back Office
Today, by using new Maintenance Methods, enterprises aim to minimize technical problems that may occur with planned maintenance, increase the efficiency of the production process and prevent the occurrence of cost-increasing effects. Naturally, in addition to a modern Maintenance and Repair Management System, a good inventory and logistics management becomes important. This is possible with a fully integrated Business Management Software.
BSOFT Maintenance has a fully integrated Back Office software consisting of professional software modules both within itself and with the Maintenance and Repair Module. You can follow all processes from Inventory Transactions to Purchasing, from Current Accounts to General Ledger, make your cost calculations, budget comparisons and get your logistics reports.
NETSIS Integration
BSOFT Maintenance has a successful integration with NETSİS, the ERP leader among local software. This integration is not only limited to the Maintenance and Repair Module, but also includes other modules within BSOFT Maintenance Maintenance and Repair Management System.
Different Back Office Integrations
Project-based integration works were also carried out with domestic ERP software such as (LOGO, etc.) and successfully finalized.
Modules
Maintenance and Repair Operations
With the developing technology, the functions of machines in production are increasing day by day. This increase has brought the necessity of establishing and managing the maintenance and management systems of the machines in the best way as well as the benefits it provides. Unfortunately, enterprises that cannot establish good maintenance management systems of their machines face a series of problems such as disruption of their production and increase in costs.
In this sense, BSOFT Maintenance Maintenance and Repair Management System Software, developed to produce solutions to the problems mentioned above, has been prepared by considering all the needs and problems faced by businesses in this field.
BSOFT Maintenance Maintenance and Repair Management System Module, which we have developed quite comprehensively, ensures that the activities carried out for the maintenance of the facilities, machines, other tools and equipment of your business at certain times and for the elimination of malfunctions that occur unexpectedly, are planned, realized and recorded in a regular manner.
The main objective of BSOFT Maintenance Maintenance and Repair Moduleis to increase the efficiency of the production process by minimizing the malfunctions that may occur in plant, machinery and other tools and equipment in continuous production and especially in process manufacturing with planned maintenance.
Contents as Main Headings
- You will be able to identify the machines you use in your business and you will be able to track these machines in a very detailed way, from serial number to the department in which they are used, from electrical power consumption to the date of assembly,
- With the user authorization module, you will be able to give detailed authorizations to your users,
- If MARS is integrated with its own modules, you will be able to open an unlimited number of warehouses for the control of your materials and spare parts thanks to its multi-warehouse operation feature,
- You will be able to define minimum and maximum stock levels for your materials and spare parts and track stock according to these levels,
- You will be able to identify your personnel working in the warehouse and maintenance departments and track who intervened in which malfunction,
- You will be able to enter your orders on warehouse and department basis and track their completion status,
- You will be able to keep records of breakdowns and repairs of broken machines and get very detailed reports about them,
- You will be able to keep track of the machines and parts sent for maintenance and receive reports,
- You will be able to define maintenance periods for your machines and enable the system to automatically alert you for these maintenance,
- You will be able to assign work orders to departments and personnel for planned maintenance and monitor their results,
- You will be able to design reports according to your own wishes, save them with different names and use them whenever you want,
The content of the main functions to be included in the Maintenance and Repair Management System is summarized below;
GENERAL DEFINITIONS
- General Parameters:
General parameters used in the program are defined. Integration information, time and currency units - Location Definitions:
Location Definitions are made for the machines to be maintained and repaired. - Personnel Definitions:
Personnel’s personal information, contact information, working hours - Shift Notes:
Notes for the next shift at shift change - Request Form:
Purchase Request Form - Energy Management:
Electricity, Water, Natural Gas Expenses Monthly Invoice Tracking - Fault Descriptions:
Machine / Vehicle independent general Fault Descriptions - Maintenance Definitions:
Machine / Vehicle independent general Maintenance Definitions - Instruction Information:
Definitions of Breakdown / Maintenance instructions and Safety Instructions used in breakdowns and maintenance - Code Definitions :
Features that can be dynamically added and updated within the entire Maintenance and Repair System - Machine / Vehicle Definitions :
Definitions of all elements in the Maintenance and Repair System. Sub definitions of these elements:
- Equipment Information : Equipment of the machine / vehicle
- Location Information : List of all current and previous locations of the Machine/Vehicle
- Spare Parts Information : Spare Parts List of the Machine / Vehicle
- Safety Equipment :
- Consumption Information : List of materials consumed periodically by the machine / vehicle
- Insurance Information :
- Tax and Inspection information :
- Work Accident Information : Date, Personnel involved in the accident and Attached Documents
- Meter Information : Meter values of the Machine/Vehicle read on the dates, if any
- Driver Information : List of Personnel who can use the Machine / Vehicle
- Accessory Information :
- Predictive Maintenance Machine Measurement Information : Predictive Maintenance Definitions that can be applied to the machine / vehicle and its equipment
- Predictive Maintenance Analyses : Analyzes made for predictive maintenance of Machinery / Vehicles and Equipment
- Technical Specifications of the Machine – Plant
- Purchase Date, Cost, Company Information, Condition (Used, New)
- Depreciation Tracking
- Who took part in the procurement, comparison forms, information on other companies
- Transportation information of the machine (Dimensions, Weight), What method and tool was used for placement (how many tons of crane or forklift)
- Location information of the machine/facility (Where is it now, where was it in the past)
- Product (Machine) tree and technical specifications of each item (Power, Speed, Material, Current/Voltage, Frequency, Sensitivity etc.)
- List of important spare parts (codes, deadlines, information of companies to be supplied, prices)
- Warranty Period Tracking
- New device Warranty Period Tracking
- Repair – Revision Warranty Period Tracking
- Whole machine
- Tracking the warranty period of the repaired, serviced or replaced part of the machine
- Warranty Expiry alarm
- Machine / Facility Revisions
- Changed parts
- Additions
- Machine/Facility Files Folder
- Illustrations
- PLC Programs
- Images Vs
- Occupational Accidents Occurring in the Machine/Facility (Direct transition feature to the OHS report in the Personnel Program)
- List of safety equipment for the machine/facility
- Machine/Facility periodic control Plan
- Machine/Facility Lubrication Plan
- Instructions for the Machine/Facility
- Operating Instructions
- Safety Instruction
- Hazardous Chemicals
- Lock Out – Tag Out Requirements and LOTTO plan
- List of Personal Protective Equipment to be used while working on the Machine / Test
- Environmental Aspects of the Machine/Facility
- Waste
- Emissions (Emission Values)
- Oils (type, quantity etc.), Invoice values
- Chemicals (type, Quantity[kg/yıl])
- Waste Water
- Technical analysis Values
- Invoice Records
- Solid Waste
- Paper-Cardboard Waste quantities and Invoice Value
- Nylon Waste Amount and Invoice Values
- Electronic waste quantities and Invoice Values
- Other solid waste
- Contaminated Waste
- Contaminated Waste quantities and Invoice values
- Contaminated Cloth Waste Amounts and Invoice Values
- Natural resource utilization
- Air (m^3/min, bar, Quality)
- Su
- (m^3/min, bar, C, Hardness, Quality)
- Monthly Invoice Records
- Installed Electric Power Consumption (kW at Load, kW at Idle)
- Chemical (list)
- Natural Gas (Nm^3/h, mbar)
- Noise (dBA)
- Machine Operating Performance
- Committed OEE values
- Realized OEE values (daily)
- Waste
DEFINITIONS OF GOVERNANCE
- Database Connection Settings
- User Location Rights:
Management of rights that allow the user to see the Machine / Vehicle Park, Work Requests and Work Orders - Personnel Notification Location Rights:Management of Personnel rights used by
Notification Service. (When a work request is entered, when a work order is created, reminders of scheduled maintenance …) - Information Location Rights by Positions:
Management of the rights based on the Personnel’s Job Position, not based on the Personnel used by the Information Service. - Log Management:
Management of all transactions, events and exceptions made within the MARS application
INCIDENTAL MAINTENANCE
- Failure Notification (Work Order)
- Workshops and departments notify the malfunction in the computer environment
- Printouts from the printer in the Maintenance Department
- Ability to order urgency
- Creation of main and sub work orders
- Trade without Job orders for very small jobs
- Work Order Approval, Assignment
- Troubleshooting
- Records of the work done
- Personnel employed and their duration
- Root cause investigation
- Materials used and their costs
- Total cost of failure
- Safety warnings
- Technical warnings
- Recording the changes made
- Closing the Failure Work Order
- Master-Foreman Approval
- Related Workshop Supervisor Approval
- Maintenance Supervisor Approval
- Pending Failure
- Waiting due to Purchase
- Order Form Information and Deadline
- Price
- External Service – Supplier Sourced
- Order Form Information and Deadline
- Company Information
- Price
- Maintenance Based
- Revision
- Machine Running, Fault Will Be Tracked
PERIODIC MAINTENANCE
- Preventive Periodic Maintenance
- Automatic Work Order Opening
- Daily, Monthly, Quarterly, Semi-annual, Annual Machine Maintenance Lists
- Control Form Lists in ISO 9000 Document System
- Spare parts, Materials, Personnel and time information used
- Safety Alerts
- Warning/Alarm module
- Legal Periodic Controls
- Automatic Work Order Opening
- Control Form Lists in ISO 9000 Document System
- Warning/Alarm Module
PREDICTIVE MAINTENANCE
- Automatic Work Order Opening
- List of Predictive Maintenance Machines and devices, values of predictive maintenance parameters
- Registry Cards of Predictive Maintenance Tools
- Predictive Maintenance Instructions
- Safety Alerts
- Predictive Maintenance Results
OPERATOR MAINTENANCE
- Compatibility between Operator Maintenance Forms and forms in ISO 9000 Documentation System
- Safety Alerts
- Operator Maintenance Approvals
BENCH LUBRICATION CARDS
- ISO 9000 Documentation System Structure
OPERATIONS
- Work Requests – Work Order: A Work Request is created for any maintenance, malfunction or revision/renewal reason.
- The master in the department may deem the request inappropriate and cancel it (Request Closes). Or he/she approves the request and the request appears on the Maintenance and Repair Supervisor’s screen.
- The Maintenance and Repair Supervisor may deem the request inappropriate and cancel it (Request Closes). Or he/she turns the request into a work order.
- After Work Order Formation;
- Maintenance, Breakdowns, Manufacturing and Revisions made within this work order,
- Personnel working for Maintenance, Breakdown, Manufacturing and Revision, working times, Materials used, Machine Downtimes, Job Descriptions and External Service Information can be defined and tracked.
- In this process, the work order status can be changed to facilitate tracking (Waiting for External Service, Waiting for Material, Waiting for Approval, Waiting for Personnel.)
- After the work order is completed, the work order is closed and authorized persons are notified via the notification service (Mail, SMS, Fax)
- When necessary, the Work Order can be reopened and job descriptions can be made.
- Work Order : For operations that do not need to create a Work Request, a Work Order can be created and tracked directly.
- Periodic Maintenance Plans : The maintenance that needs to be done to the Machines / Vehicles based on Counter or Date can be scheduled periodically. The Machine / Vehicle can be scheduled for maintenance on fixed dates (01.01.09; 01.07.2009), periodic dates (every 3 months) or, if it is monitored on a counter basis, on fixed counters (10 thousand, 50 thousand) or periodic counters (every 10 thousand).
- Date or Counter Based scheduled maintenance can be converted to Work Order individually or collectively.
- Work Orders created from periodic maintenance reschedule their Periodic maintenance when they are closed
- Meter Update : The counters of the Machines / Vehicles on which counter tracking is performed are updated with estimated or actual values.
STOCK and CURRENT TRANSACTIONS
- Main Groups
- Material Information
- Warehouse Codes
- Inventory Entry and Exit Transactions
- Stock Deputy Imaging
- Current Card Information
PURCHASE ORDER FORM AND ORDER RECORDS
- Opening an order (Filling in and signing the Purchase Form)
- Recording the completed form, linking it to the relevant work order
- Business card holder with service, company supplier etc. contact information
ENERGY MANAGEMENT
- Invoice records
- Monthly Electricity Bills
- Monthly Natural Gas Bills
- Monthly Fuel Bills
- Electric Energy
- Daily consumption information
- Daily CosW information
- Consumption Breakdown
- Workshop-based distribution
- Device-based distribution
- Resistances
- Lighting
- Engines
- Compressors
- Natural Gas
- Consumption Breakdown
ALARM MODULE
- Periodic Controls
- Warranty Periods
- Low Stock levels
- Lubrication / Filter Change Times
- Management Programs Terminals
- Staff-created special alarms
SECURITY MODULE
- Lock Out – Create a Tag Out Procedure,
- Hazardous Machinery and Plant Identification and tracking
- MSDS of hazardous materials
- Linking Work Orders and Safety Plans
- Personal protective equipment Usage List
PERFORMANCE INDICATORS
- Machine/Facility Shutdown Report
- Incidental Maintenance Times
- Periodic Maintenance Schedules and realization rates
- Staff Performances
- Monthly Turnover /Monthly Maintenance Cost
REPORTS
A reporting wizard is available within MARS and reports can be retrieved selectively as visual graphs (bar, pie, curve, etc.) and lists.
- Machine/Facility list
- Component lists (BOM)
- Material Utilization Report
- Distribution report of maintenance according to work types
- Maintenance Cost Report by Machine
- Analysis of the most
- Failure status graph on monthly basis
- Monthly Maintenance costs Report
- Stance Reports
- Depreciation Report
- Energy consumption Report
- Energy Cost Analysis Report (Total energy consumption / Turnover)
- The desired report with the selection of the desired parameters
SCREENSHOTS
- Manager Screens
- Standing Machines and Plants, Reasons for stopping, Troubleshooting Terminals
- Standard Report Icons
- Monitoring critical machine tools
- Maintenance Department Screens
- Fault tracking screen
- Alarm Screen
- Pending faults screen
- Reporting
- Legal Periodic Maintenance
- Stock
- Order Form
- Monitoring Management Programs
- Energy management
- Workshop and Department Supervisors screens
- Fault reporting
- Monitoring own failures
- Standard report icons
- Loom registration records
Information Transactions Module
BSOFT Maintenance Maintenance and Repair Program is the module that makes all kinds of alerts (work request, work order formation changes, planned maintenance times, predictive maintenance warnings, etc.) to the people and persons you want via SMS, Mail, Pop Up.
Mobile Transactions Module
It is a software module that enables many operational operations in BSOFT Maintenanceto be performed on mobile devices and can also communicate with BSOFT Maintenance Information.
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