Project Description
Biltaş Maintenance & Repair System
BSOFTmars is a modern software that manages your company’s maintenance operations of machinery, buildings, equipment etc…
Biltaş Bakım ve Onarım Çözümleri
ERP sistemleri ile tam entegre.
Şirketinizin Bakım masraflarını BSOFTbakım ile %80 oranında azaltın!
- Tesis ömrünü artırır.
- Üretim sürekliliğini sağlar.
- Kolay kurulum ve kısa sürede devreye alınır.
- Periyodik Bakım
- Kestirimci Bakım
- Arızi Bakım
- İş emirleri
BSOFTbakım, işletmenizin makine, bina, teçhizat v.b. ekipmanlarının bakım operasyonlarını yapan modern bir Bakım ve Onarım yazılımıdır.
Nowadays, enterprises, equipment / machinery and equipments make big investments and therefore they want to compensate for these investments. And by using the new Maintenance Methods, they aim to minimize the technical problems that may arise in the planned maintenance, to prevent the increase of the efficiency of the production process and the increase of costs.
Maintenance is the whole of the functions performed to maintain the functions of the equipment and systems in operation at the highest performance level. Maintenance activities should be directed to 4 basic reasons;
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Reducing production cost,
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Contributing to product quality
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Increase facility lifetime
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To ensure continuity of production
With the new maintenance methods, the calculation of labor and spare parts needs, the automatic creation of maintenance work orders for periodic maintenance, the follow up of the work orders that are formed, the actual workforce used in the maintenance work and the spare parts are entered into the system and the related maintenance personnel are warned before the periodical maintenance.
For periodical maintenance, both labor and spare part needs are determined and probable bottlenecks can be detected, and unnecessary stocks can be avoided and inventory cost can be avoided. In addition, the actual costs incurred in maintenance work orders can be examined in detail. Different calculation reports and graphs allow cost analysis to be carried out.
Operators using the New Maintenance Methods provide periodic maintenance of facilities, machinery, other equipment and equipment, so that the activities carried out to eliminate unexpected failures can be planned and recorded on a regular basis.
The purpose of the New Maintenance Administration is to ensure that all fixtures that are present in an enterprise and incur expenses for maintenance costs; With the help of modern methods, to ensure that they are ready for use with the longest life, without any failures and with the least cost. And it improves the productivity of the production process by ensuring that the problems and problems that can be born are brought down to the lowest level, especially in the companies that perform uninterrupted production.
In the enterprises where the Maintenance Management is implemented correctly; While equipment (fixtures) are fully responsive, equipment maintenance costs are less than 10% of total production costs. This value can be reduced to 3% or even 2% depending on the level of maintenance and the type of plant.
As a result, Contemporary and Modern Care Management is a fairly new concept that is being implemented in businesses. In terms of Contemporary and Modern Care Management; Is understood as a management system that uses modern maintenance methods as well as modern maintenance equipment and modern management systems as a whole and as a whole.
BSOFTmars, designed to support new, contemporary and modern maintenance methods we tried to outline above, and developed with today’s technology, is a modern Windows based Maintenance and Repair Management System consisting of several modules integrated with each other.
BSOFTmars – MAINTENANCE & REPAIR MANAGEMENT SYSTEM
BSOFTmars,provides maintenance reports, repairs, workmanship, material consumptions, external maintenance costs, failure statistics, malfunctions, maintenance done outside the company, etc.(Windows) and C # (.net) application software that supports various types of maintenance, integrated with each other and sub-modules.
BSOFTmars Maintenance Program;
- It enables maintenance work to be done on time and economically,
- All failures are kept in record and the financial burden of each failure is monitored,
- The periodic maintenance model ensures that the planned maintenance of each machine is kept under control and the machine life is increased,
- Thanks to the periodic maintenance model, it provides the necessary work force and spare part needs to be determined in advance,
- Thanks to the periodic maintenance model, planners can make a healthier production plan,
- The predictive maintenance model ensures that the measurement values for each machine are entered and that automatic maintenance instructions are issued in the specified tolerance range, ensuring that the machines are protected from possible malfunctions,
- The machine group and machine and work orders provide maintenance costs (workmanship and materials)
- Security and Work Instructions allow for the reduction of the probability of making mistakes, the increase of labor productivity, and the establishment of the “KNOWLEDGE BANK”
- It ensures the monitoring of the performance of maintenance personnel,
- Provides maintenance statistics and machine life reporting when maintenance histories are kept,
- Through the warning system, it provides effective notification of information that affects production, open accident workers, open planned maintenance workers, pending job demands, past maintenance, overcoming maintenance and critical stock levels,
- It allows you to get an unlimited number of graphical reports (most of them, stops, failures etc).
BSOFTmars provides these maintenance methods
- Periodic Maintenance
- Predictive Maintenance
- Malfunction Maintenance
Periodic Maintenance:
Considering the past performance and operating conditions of the equipment / machines and the experience of the maintenance team, it is determined at what time intervals the equipment / machine will be stopped and taken away. That is to say, periodic protective care. Multiple maintenance descriptions can be specified for each equipment / machine to be maintained. This maintenance method is generally the most commonly used maintenance method in the industry today. In the same way, it is determined which parts are to be replaced on the machine, which is based on the inspection, and these parts are made available.
Predictive Maintenance:
Estimated maintenance is the comparison of selected parameters for measuring, analyzing and correcting defects in machinery and equipment before they become problematic, using graphical trends with measured and predefined limit values. That is, maintenance based on machine performance. In other words, Predictive Maintenance Technique; It responds early and ensures that it can be corrected in less time,in scheduled stops, without giving any maintenance delay. The approach used is to predict future situations by monitoring the current and past situations of machinery and equipment.
The main principle here is to monitor the performance of the machines during production and determine when to look at them, and to shorten the production period and repair the predetermined fault. Some parameters are checked and measured without stopping production in the framework of the program, taking into account the character and operating conditions of the machine. After the fault is diagnosed, the necessary spare parts are procured, production is stopped, maintenance is carried out as soon as possible and reproduction is continued.
Malfunction Maintenance:
It includes maintenance and repairs made when the equipment / machine stops due to an unexpected failure. In other words, maintenance is done when the fault occurs. In general, this method of care; It can be applied in plants and workshops with many redundant machines and with less expensive machines. However, the main disadvantage of this maintenance method is that it is very difficult to make a real production plan, since it is not known when the damage will come to fruition.
General Properties
- BSOFTmars can be installed on Server or PCs (Client) depending on demand and need.
- The database is always located on the Server. There is no information storage on the client side.
- Authorization at BSOFTmars is top level. All users can open and use BSOFTmars with their own passwords.
- Authorization to use BSOFTmars can be done.
- Full authority
- Ability to report failures and related department records and reports
- Managerial authorities (can see all reports, fault priority, etc.)
- Forms, Lists, Cards, Reports, and Instructions used in BSOFTmars complies with the applicable Quality Management System on the market.
- Offers unlimited reporting. In addition to the hundreds of reports it contains, BSOFTmars provides the user with the ability to prepare and add the report to the structure thanks to its reporting program.
- Thanks to the filtering structure in the reports, the user gets different analytical and graphical results.
- It has a log system. All logs, changes and deletions made in BSOFTmars are kept. Easily reported.
- BSOFTmars is compatible with ISO 9000, ISO 14000, OHSAS 18000, TPM 5S, 6 SIGMA management systems and can meet all the requirements of these systems.
- All reports in BSOFTmars can be converted to word, excel, pdf, html, mht and rtf documents.
Fully Integrated Back Office
Today, businesses are using new Maintenance Methods to minimize the technical problems that may arise in planned maintenance, to increase the efficiency of the production process and to prevent the costs from increasing. Naturally, a modern maintenance and repair management system as well as a good stock and logistics management gain importance. This is possible with a fully integrated Business Management Software.
BSOFTmars has a fully integrated Back Office software, which consists of professional software modules, in-house and also with the Maintenance and Repair Module. You can track all processes from Inventory to Purchase, from Current Accounts to General Account, you can make your cost calculations, budget comparisons and logistics reports.
Netsis Integration
BSOFTmars has a successful integration with NETSIS, the ERP leader in local software in Turkey. This integration is not limited to the Maintenance and Repair Module but includes other modules included in the BSOFT Maintenance and Repair Management System.
Other Back Office Integrations
Again, project-based integration studies have been done with the software (LOGO etc.) included in the domestic ERP software and it has been concluded successfully.
BSOFTbakım-Mars BroşürModules
In this sense, the BSOFT Maintenance and Repair Management System Software, developed to solve the above mentioned problems, is prepared considering all the needs and problems faced by the operators in this area.
The BSOFT Maintenance and Repair Management System Module, which we have developed quite extensively, ensures that regular maintenance, recording and recording of the maintenance activities of our own facilities, machinery, other tools and equipment, and unscheduled defects are recorded regularly.
The main goal of the BSOFT Maintenance and Repair Module is to increase the productivity of the production process by minimizing the failures that may occur in the plant, machinery and other tools and equipment in the continuous production and especially the process production by the planned maintenance.
Content as Main Headings
- You will be able to identify the machines that you use in your business and you will be able to follow these machines in a very detailed way from the power consumption to the installation date,
- With the user authorization module, you can give detailed authorization to your users,
- If MARS is integrated with its modules, you can open an unlimited number of warehouses for the control of your materials and spare parts thanks to the multi-warehouse operation feature,
- You will be able to define minimum and maximum stock levels of materials and spare parts and make inventory according to these levels,
- You will be able to define your personnel working in warehouse and maintenance departments and follow who is interfering with which fault,
- You will be able to enter your warehouse and department-based orders, track their completion status,
- You will be able to keep records of breakdowns and repair of malfunctioning machines, receive detailed reports on them,
- You will be able to follow up and receive reports on machines and parts sent out to you,
- You will be able to define maintenance periods for your machines and you will be able to have the system automatically alert you for these maintenance,
- For the care you plan, departments and staff can assign work orders and you can monitor their results,
- You will be able to design reports according to your own wishes, save them with different names and use them at any time,
The contents of the main functions to be included in the Maintenance and Repair Management System are summarized below;
GENERAL DEFINITIONS
- General Parameters:
General parameters used in the program are defined. Integration information, time and currency units - Location Definitions:
Location Definitions of the machines to be repaired. - Staff Definitions:
Personnel personal information, contact information, overtime fees - Shift Notes:
Notes to the next shift in shift change - Request form:
Purchase Request Form
Energy Management:
Electricity, Water, Natural Gas Expenses Monthly Invoice
Fault Definitions:
Machine / vehicle independent General Fault Definitions - Maintenance Definitions:
Machine / Vehicle independent General Maintenance Definitions - Instructional Information:
Fault / Maintenance instructions and Safety Instructions definitions used for faults and maintenance - Code Definitions:
Dynamically added and updated features within the All Maintenance and Repair System - Machine / Vehicle Definitions:
Definitions of all the elements in the Maintenance Repair System. Sub-definitions of these Elements: - Equipment Information: Machine / Vehicle Equipment
- Location Information: List of all current and previous locations of the machine / vehicle
- Spare Parts Information: Machine / Vehicle spare parts list
- Security Hardware:
- Consumable Information: List of materials consumed periodically by the machine / vehicle
- Insurance Information:
- Tax and Inspection information:
- Work Accident Information: Date, Accident Staff and Attached Documents
- Counter Information: If present, the counter values read in the Machine / Vehicle Date
- Driver Information: List of personnel who can use machine / tool
- Accessory Information:
- Predictive Maintenance Machine Measuring Information: Predictive Maintenance Machine Estimations / Car and Equipment
- Predictive Maintenance Analyzes: Analyzes made for estimating maintenance on Machine / Vehicle and Equipments
- Machine – Plant Technical Specifications
- Purchase Date, Cost, Buying Company Information, Status (2nd Hand, New)
- Depreciation Follow-up
- Who was involved in the purchase, comparison forms, information of other companies
- Shipping information (Dimensions, Weight) of the machine, Which method and tool was used when placing (several tons of cranes or forklifts)
- Machine / plant location information (Where is now, where in the past was)
- Product (machine) tree and technical specifications of each floor (Power, Turnover, Material, Current / Voltage, Freq., Sensitivity etc.)
- List of important spare parts (codes, term dates, information of the companies to be supplied, prices)
- Warranty Period Follow-up
- New device Warranty
- Repair – Overhaul Warranty
- All machine
- Warranty period follow-up of the machine’s repairing or servicing or changing parts
- Warranty Period End alarm
- Machinery / Plant Overhaul
- Changing parts
- Insertions
- Machine / Files folder
- drawings
- PLC Programs
- Pictures Vs
- Machine / Accidental Work Accidents (direct pass to OHS report in Personnel Program)
- List of security equipment belonging to machine /
- Periodical inspection plan of machinery / plant
- Machine / Plant Lubrication Plan
- Operating Instruction
- Safety Instruction
- Hazardous Chemicals
- Lock Out – Tag Out Requirements and LOTTO plan
- List of personal protective equipment to be used when working on the machine / test
- Environment aspects of machinery / plant
- Waste
- Emissions (Emission Values)
- Oils (gender, quantity, etc.), Invoice values
- Chemicals (gender, Amount [kg / yr])
- Waste water
- Technical analysis values
- Billing Records
- Solid Waste
- Paper-Carton Waste Amounts and Invoice Value
- Nylon Waste Quantity and Invoice Values
- Electronic waste quantities and invoice values
- Other solid wastes
- Contamine Waste
- Contamine waste quantities and invoice values
- Contaminant Waste Quantities and Invoice Values
- Use of natural resources
- Air (m ^ 3 / min, bar, Quality)
- Water
- (M ^ 3 / min, bar, C, Hardness, Quality)
- Monthly Invoice Records
- Installed Electric Power Consumption (kW at load, kW at idle)
- Chemical (list)
- Natural Gas (Nm3 / h, mbar)
- Noise (dBA)
- Machine Performance
- Committed OEE values
- Actual OEE values (daily)
MANAGEMENT DEFINITIONS
- Database Connection Settings
- User Location Rights:
Manage the rights that allow the user to view Machine / Vehicle Park, Work Requests and Work Orders - Personnel Disclosure Location Rights:
Management of Personnel Rights used by the Disclosure Service. (When a job request is entered, when a job order is created, in Planned Care Reminders …) - Information according to positions Location Rights:
Management of Employee Job Position based rights, not personnel based on the Disclosure Service. - Log Management:
Management of all transactions, events and exceptions within MARS application
MALFUNCTION MAINTENANCE
- Failure Notification (Work Order)
Computer environment failure reports of workshops and departments
Removing printouts from the maintenance department
To give order of urgency
Creation of main and sub work orders
Ability to perform job orderless operations for very small jobs - Work Order Confirmation, Assignment
- Defect Removal
Records of work done
Employees and their duration
Root cause investigation
Materials used and their costs
Total failure cost
Safety warnings
Technical warnings
Registration of changes made - Failure to Disable the Work Order
Master-Foreman Approve
Relevant Workshop Chief Approval
Maintenance Supervisor - Waiting for a fault
Standby with Buying
Order Form Information and Termin
Price - Outside Service – Supplier Originated
Order Form Information and Termin
Company Info
Price - From Maintenance
Revision
Machine Running, Fault Followed
PERIODIC MAINTENANCE
- Protective Periodic Maintenance
- Automatic Job Opening
- Daily, Monthly, Tri-monthly, Six-Monthly, Annual Machine Maintenance Lists
- List of Control Forms in ISO 9000 Document System
- Spare parts, materials, personnel and time information used
- Security Alerts
- Warning / Alarm module
- Legal Periodic Controls
- Automatic Job Opening
- List of Control Forms in ISO 9000 Document System
- Warning / Alarm Module
PREDICTIVE MAINTENANCE
- Automatic Job Opening
- List of Estimated Maintenance Machines and Devices, Values of Estimator Maintenance Parameters
- Predictive Maintenance Tools Register Cards
- Predictive Maintenance Instructions
- Security Alerts
- Estimation Results
OPERATOR MAINTENANCES
- Operator Maintenance Forms and forms in the ISO 9000 Documentation System
- Security Alerts
- Operator Maintenance Approvals
BENCH LUBRICATION CARDS
- ISO 9000 Documentation System Structure
OPERATIONS
- Job Requests – Work Order: Any request for maintenance, malfunction or overhaul / renewal is created by the Work Request.
- The master can see the unsuitable request in the department and cancel it (Request Close). Or the request for approval and request falls on the Maintenance Repair Chief’s screen.
- Maintenance Repair Chief can see the request unsuitable and cancel (Request Closed). Or turn the demand to business order.
- After Work Order;
- This work is made in order of Care, Malfunctions, Manufacturing and Revisions,
- Personnel working for Maintenance, Failure, Manufacturing and Revision can be followed up by defining working time, Materials Used, Machine Stop Time, Job Descriptions and Outside Service Information.
- This process can be facilitated by changing the work order status. (Waiting for Outside Service, Waiting for Material, Waiting for Approval, Staff Waiting.)
- After the Job Order is completed, the job order is closed and the authorized persons are informed via the information service (Mail, Sms, Fax)
If necessary, the Job Order can be reopened and job descriptions can be made.
- Work Order :Direct work order can be created and followed for operations which dont need to create work order
- Periodic Maintenance Plans : Machine / Vehicles Counter or Date based maintenance can be scheduled periodically. If the machine / vehicle is being monitored on fixed dates (01.01.09; 01.07.2009), on periodic dates (every 3 months) or on counter basis (10bin, 50k) or on periodic counters It can be planned.
- Date or Counter Based planned maintenance can be converted individually or in batch to Work order.
Work Orders created from periodic maintenance will re-schedule periodic maintenance
- Date or Counter Based planned maintenance can be converted individually or in batch to Work order.
- Counter Update : The counters of machines / vehicles on which the counter is set are updated with estimated or actual values.
STOCK & CURRENT PROCEDURES
- Main Groups
- Material Information
- Warehouse Codes
- Stock Input and Output Operations
- Stock Submissions
- Current Card Information
PURCHASE ORDER FORM AND ORDER REGISTER
- Opening the order (filling out the Procurement Form and issuing the signature)
- Registration of the filled-in form, connection to the relevant work order
- Service, company supplier etc. Business card with contact information
ENERGY MANAGEMENT
- Bill Registers
- Monthly Electricity Bills
- Monthly Natural Gas Bills
- Monthly Fuel Bills
- Electricity
- Daily consumption information
- Daily CosW information
- Consumption Distribution
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- Workshop-based distribution
Device-based distribution -
- resistances
- Lighting
- engines
- compressors
- Workshop-based distribution
- Natural Gas
- Consumption Distrubition
ALARM MODULE
- Periodic Controls
- Warranty Periods
- Low Stock levels
- Lubrication / Filter Change Times
- Management Programs Terminals
- Special alarms created by staff
SAFETY MODULE
- Lock Out – Create Tag Out Procedure,
- Identification and follow-up of Hazardous Machinery and Facilities
- MSDS of hazardous materials
- Associating Work Orders and Safety Plans
- List of Personal Protective Equipment
PERFORMANCE INDICATORS
- Machine / Plant Stop Report
- Malfunction Maintenance Times
- Periodic Maintenance Times and Implementation Rates
- Staff Performance
- Monthly Turnover / Monthly Maintenance Cost
REPORTS
BSOFTmars has a reporting wizard and reports can be visualized (bar, paste, curve, etc.) and listed.
- Machinery / Facility List
- Component lists (Product tree)
- Material Usage Report
- Distribution report of work types by maintenance
- Machine Based Maintenance Cost Report
- Maximal analysis
- Monthly breakdown situation graph
- Monthly Maintenance Costs Report
- Posting Reports
- Amortization Report
- Energy consumption report
- Energy Cost Analysis Report (Total Energy Consumption / Turnover)
- Desired report with selection of desired parameters
SCREENSHOTS
- Director Screens
- Stopped Machinery and Facilities, Reasons for Stopping, Troubleshooting Terminals
- Standard Report Icons
- Monitoring of critical machines
- Maintenance Department Screens
- Fault tracking screen
- Alarm Screen
- Pending failures screen
- reporting
- Regular Periodic Maintenance
- Stock
- Order form
- Monitoring of Management Programs
- Energy management
- Workshop and Section Officers screens
- Failure reporting
- Tracking your own failures
- Standard report icons
- Machine registry records
