Industry : Process Industries

Some of the Solutions that we have for the Process industries include:

  • Operations Log book This Solution is designed to Digitize the Operations Log book requirements of the Plant. The System is modular and comes with various features for Operations Log entry, Shift Handover, Management View and coes with Rich Analytics that help indecision Making.
  • Reliability based Maintenance Management System Meant for automating the Maintenance Workflow in the Organization
  • Incident Management System Meant to track and Analyze all Incidents in the Plant and Identify Continuous Improvemet actions aimed at Minimizing the Incidents
  • Reliability Analytics and Benchmarking Platform Meant for the Reliability Team to Monitor the Asset Failure Patterns and Key Performance Indicators such as Time to Repair, Time between Failure, Cost of maintenance etc. The System can be used to Benchmark the Equipment Performance and also Identify action Items for Improving the Uptime of Equipments. The State of art Statistical Analysis helps in Quantifying the Improvements done over a Period of time

Operations Log Book

While there is a good thrust from Various Manufacturing Industries to Automate the Core Functions / Operations, the maintenance of the Daily Operations Log is still not automated by many Organizations. In most cases the daily Log books are updated manually. Some of the Challenges faced by organizations include:

  It is difficult to retrieve past data based on Events and it is a cumbersome task to manually surf through the Voluminous Log Book
  There is no Systematic Tracking and closing of Action Items and it is left to the Operations Staff to track the closure Manually
   This Presents a Potential loss in Efficiency due to adhoc tracking and monitoring of Action Items
  Since the Entry is Manual, there is a scope for erroneous entry
  Since different sections in the log book refer to different source of data (e.g. Process Data, Quality, Defects , Reliability etc), this provides a good scope for automatic update of the data from different systems
  The Inputs from the Operations Log itself can be taken as a Source for Continuous Improvement Initiatives.
  Also the Time Consumed by the staff works to around 1.5 Hrs per department per day in collating the Operations Log book and also consume 2500 Sheets of paper on Monthly basis
  Seamless Communication to Stakeholders on the discussion points and follow up’s and related status is ad-hoc All the above present a good case for the benefits that can be realized on Automating the Log Book Process


Conceptual Overview


operation logbook overview

The Solutions is modular and comes with modules for

I. Operator Entry for Shift log
II. Shift Handover ( between Incoming and outgoing Shifts)
III. Daily Operations Visualization, Monthly Trends and Analytics for management
IV. API Interface to Integrate other Systems (data from DCS, LIMS, EMS, Tanks, SAP) to the Log book

   The Solution provides a simple and effective way of digitizing the Manual Operations Logbooks by eliminating the paper, binders, manual bookkeeping etc.
   Carryout effective and safe shift handovers.
   Delegate operational instructions to respective teams.
   Access and View Logbooks from anywhere in Plant and from HQ.
   Provide Data Analytics, Trends, Dashboards, Reports and Notifications etc..





Architecture view of the Digital Log Book

operation logbook Architecture overview

Benefits of the proposed Solution:

   Make Operations Data more Valuable
   Scalable Solution. Easy to Roll out the same for multiple Plants within the Site
   Saves cost of material and paper
   Reduces time and efforts of logistics and housekeeping of manual logbooks
   Easy consolidation and quick searching data, events and activities etc.
   Optional Integration of Reliability Analysis and Incident Management Systems to Monitor and Drive Improvements
   Capability to Benchmark the Overall performance of KPI’s over different Timelines
   Quantify the Improvements that can be generated using the System
   Positively Impact Business Results:
        Increased Profits
        Avoid Unplanned Downtime
        Increased Safety
        Reduction in no of Defects

Infomine IMS

This is an Incident Management System that can be used for analyzing the emergencies faced by the Plant.

During the normal day to day operations in a plant, there are many emergencies faced that have resulted in the trip of the plant. This system can be used to record the emergencies along with the root cause and also document the corrective and Preventive actions that need to be taken.

The Preventive actions documented can also be tracked to closure thereby ensuring that reoccurrence of emergencies which are similar in nature are minimized. The system comes with rich features and reports that enable the Management to take informed decision. The system also provides the user with statistical reports that aid in identifying the bottlenecks and plan for continual Improvement. The system also has the capability to benchmark the current performance and also monitor the performance at different periods of time.

Key Features:

Fast and Easy Set Up - The Administrator can Set up and Configure the System easily. The System comes with XL / CSV Uploads that can be used to set up the system rapidly. This includes

Configure various Departments
Associated Users and Managers
Define the Various Locations of the Plant
Define all the Equipment's which are maintained
The Incident Codes that are commonly used during maintenance can also be defined

Incident Entry / Update

The User can enter the details of the Incident that has resulted in the trip of the plant / Production loss.The User can enter the details along with the corrective actions taken and the Preventive actions and submit the same for review by the Moderator

Incident View by Moderator

The details of all Incident submitted by the user can be viewed by the Moderator. The status of the Incident Submitted can also be viewed. The Moderator can also give his feedback on the report or accept the report that has been submitted.

Tracking of Preventive Action

The User can quickly see the status of all Preventive actions that have been documented. Any updates to the Preventive action can also be done to ensure that the Incident recurrence is minimized

Reports

User can see various reports which are available as a part of the solution.Reports that are informative in nature and also reports that provide statistical inferences can be generated for analysis and identifying Improvement Opportunities.

Create Baseline

The User can create baseline indicating the Performance benchmark for a given period of time. The system calculates the key performance measures such as number of Incidents due to each Incident Code, Average Cost Incurred, production hours lost and Mean Time to recover for each Incident Code along with the respective standard deviation.

Compare Baselines

This feature is available only after the second baseline is created. The user can see the performance baselines over different time periods. .This allows the user to compare the performance over different time intervals. Analysis of the effectiveness of any Improvement activities that have been carried out can be done.

Deployment

What are the Deployment Options available:
Infomine MMS can be deployed in two modes:

1. On Premise Deployment

Here we provide the System in a CD as executables and the same can be deployed in your environment.

The benefit of this kind of installation is that you have full control over network access to the server and complete data privacy. The drawbacks are that this type of implementation is expensive. The IT department has to constantly look after the server, backups must be done by the maintenance team, and the software can quickly get out of date if updates aren't installed regularly

2. On Cloud Deployment

Here the System is made available Online. It is hosted on Servers which are provided by Leading players such as AWS or Microsoft Azure.

The advantage with this option is we take care of the IT, Hosting, Security and backups for the System. Patches and Updates are also done automatically.

The System can be accessed through any computer with Internet connection and browser.

Infomine MMS

This is a Reliability based Maintenance Management System that can be used for planning and scheduling equipment maintenance to meet the needs of modern plants and facilities. InfoMine-MMS incorporates the power and inherent advantages of Web based Technology, User friendly graphical user interfaces, and relational database software to automate the Maintenance workflow. The system comes with rich features and reports that enable the Management to take informed decision. The system also provides the user with statistical reports that aid in identifying the bottlenecks and plan for continual Improvement. The system also has the capability to benchmark the current performance and also monitor the performance at different periods of time.

Key Features:

Fast and Easy Set Up - The Administrator can Set up and Configure the System easily. The System comes with XL / CSV Uploads that can be used to set up the system rapidly. This includes

Configure various Departments
Associated Users
Define the Various Locations of the Plant
Define all the Equipment's which are maintained
The Problem Codes that are commonly used during maintenance can also be defined

Create / Manage Work Order

The Users can create and Manage the Work Orders easily. The System also allows the user to look at the status of each work-order and status of work assigned to Individuals. The users can also look at Active Work orders that are Open and check the status easily

Track Job History of Equipments

The Users can search for any Equipment and also look at the past history of maintenance that was performed on that equipment. This will help the user to understand the kind of Maintenance issues that has been done on the Equipment

Preventive Maintenance :

This feature can be used once the Equipment Baseline / Benchmark for Maintenance are created. The Baselines indicate various performance metrics such as Mean Time to repair, mean Time Between failure, cost of Maintenance etc for all equipments. Once the baselines are created, the user can query the system to list all equipment's that are nearing its life Time. Based on the List, the user can decide to do a preventive Maintenance proactively to ensure that the equipment is available at all times

Reports / Analytics

User can see various reports which are available as a part of the solution. Reports that are informative in nature and also reports that provide statistical inferences can be generated for analysis and identifying Improvement Opportunities

Create Baseline / Performance Benchmark:

The User can create baseline indicating the Performance benchmark for a given period of time. The system calculates the key performance measures such as Mean Time to repair, Mean Time Between Failure, Average Cost incurred towards maintenance along the standard Deviation. The above details can be viewed based on equipment or on Problem Codes.

View Baselines / Performance Benchmark:

This feature is available once the baselines are created. The User has the Options to view baseline data based on Equipment or based on Problem Codes.Quick view of the baseline data helps the user to plan the maintenance better. This gives the manager a direction on the expected time to complete the Work which can be used to plan the maintenance activity

Compare Baselines / Benchmark:

This feature is available only after the second baseline is created. The user can see the performance baselines over different time periods. The User can also get a first hand information on whether the Maintenance strategy has yielded benefits

Deployment

What are the Deployment Options available:
Infomine MMS can be deployed in two modes:

1. On Premise Deployment

Here we provide the System in a CD as executables and the same can be deployed in your environment.

The benefit of this kind of installation is that you have full control over network access to the server and complete data privacy. The drawbacks are that this type of implementation is expensive. The IT department has to constantly look after the server, backups must be done by the maintenance team, and the software can quickly get out of date if updates aren't installed regularly

2. On Cloud Deployment

Here the System is made available Online. It is hosted on Servers which are provided by Leading players such as AWS or Microsoft Azure.

The advantage with this option is we take care of the IT, Hosting, Security and backups for the System. Patches and Updates are also done automatically.

The System can be accessed through any computer with Internet connection and browser.

Reliability Analytics and Benchmarking Platform:

The Maintenance Activities in the Process Industries are currently Automated and most of the the Industries use ERP Systems to automate the Maintenance workflow that can handle:
Reactive or breakdown Maintenance
Preventive Maintenance
Condition Based Maintenance
In certain cases Predictive maintenance is also adopted

The Systems that are used to automate the Maintenance also provide basic Metrics for equipment's such as
Mean time to Repair
Mean Time Between Failure
Reasons for failure
Cost for each Work Order that is completed

While the above is a basic measure, the challenge industries face is to look at how we can use the above Information for driving Improvement Programme's across the Plant / Unit. How do you analyze the Maintenance Data and use that for arriving at a Continuous Improvement Plan that can help increase the Equipment uptime. What are the action Items that each department should do to ensure that the equipment uptime is increased from the current levels.

There is a need felt in the Industry to benchmark the (maintenance) Equipment performance across various parameters over a defined time line . Such a Benchmarking Solution will help the department Managers to look at various aspects of the equipment performance and also identify action Items that can lead to Improve the up time of their equipment's. The System should also ensure that the Action Items identified are tracked to closure thereby ensuring that the benefits of the actions taken be actually measured and quantified.

Conceptual Overview of the Solution:



Key Features:


Platform for Implementing a Continual Improvement System

API to Interface with ERP or CSV file Upload to Gather the plant Maintenance data

Create Benchmark for different Time periods. Benchmark on Equipment ID / Failure Codes created


Department level Analysis- helps in Identification of Improvement Points

Action Items to track the Improvement opportunities to closure

Cost Analysis and Comparison between different benchmarks

Benefits:

  • Make maintenance Data more Valuable
  • Have a Platform for Continual Improvement in Place
  • Facilitate the deployment of a Central Reliability Team
  • Compare performance across different Locations
  • Quantify the Improvements that can be generated using the System
  • Positively Impact Business Results:
    • Increased Profits
    • Avoid Unplanned Downtime

Industry : IT Services

SIMAINTIC This is a cloud based Service Management tool that is designed to deliv end-to-end IT Service Management functionality. The System is modular and comes with preconfigured workflows that can handle Incidents, Query Management, Service Requests, Change Requests besides Bug Fix process. The System is designed for providing application support but can also handle other business operations as appropriate

SIMAINTIC- Analytics This is a Cloud based Service Analytics tool that is designed to deliver the Analytics of the Service Management to the User. Irrespective of the Service management tool that is in place side, this Analytics tool provides an XL Interface that can help in generating the reports for taking Informed decisions

SIMAINTIC

SIMAINTIC is a cloud based enterprise grade, comprehensive IT Service Management tool. It helps business enterprises and service providers to manage service operations and ensure guaranteed service delivery to their customers as per defined service level goals.

The System comes with Rich Analytics that aid the Managers to take informed decisions aimed at improving the effectiveness and efficiency of the Service provided


Key features of the system are listed below:


Fast and Easy Set Up

The Administrator can Set up and Configure the System easily. The System comes with XL / CSV Uploads that can be used to set up the system rapidly. System is Configuration Rich. Comes with Pre Defined Workflows and Metrics thatCan be inherited by organizations


Simple and Powerful Workflow Configuration


Simple and Powerful Workflow Configuration:Workflow Configuration and Design made Simple.It is very easy to Configure Complex Workflows

On demand Metrics


On demand Metrics:On Demand Metrics and dashboard indicating the Service performance as on date

Stakeholder Communication


Stakeholder Communication: Automated Communication with Stakeholders. Configuration can be done as needed

Service level Management


Service level Management : The Service Level Agreement and tracking is based on Project Calendar.

Self Help


Self Help : The Self help Feature helps in reducing the Volume of Tickets handled. This feature also enhances the Quick Resolution for any queries that are asked

Call Tree / Alert Notification

Call Tree / Alert Notification - The System provides Just in Time Alerts to various Stakeholders notifying them of any delay in SLA Resolution that can cause breach in the committed Service Level . Timely alert provides a mechanism for review of the Issue by relevant Stakeholders thereby aiding speedy resolution


Process for Core ITIL Processes

Besides the above, process for Core ITIL Processes detailed below are also available and preconfigured in the System:

  1. Incident Management ensures that the Service is restored quickly in the event of an Incident
  2. Problem Management offers a permanent solution to the root cause Issues
  3. Change Management Change management process ensures that the change is implemented with minimum Impact on the IT Services
  4. Release and Deployment management Pre Configured Workflows are available for the Users to adopt and use
  5. Service Request Fulfillment This allows the end users to make requests and track to closure
  6. Service Level Management helps in defining the Project Calendars, track and monitor the ticket resolution based on Service Level Agreements that are defined
  7. Knowledge Management Helps in speedy resolution of Issues / tickets that are raised.

Service Desk Process flow:

Users can raise a ticket either through the Web Interface provided or by sending a mail to the configured helpdesk email id. The System creates a temporary ticket that is available for the Support manager to view. The Support Manager reviews the ticket and updates the Priority , Classification and other details that are required and assigns the same to the team member. The Updated ticket details are now available for the team member to review and act upon for closure.

Workflow Catalog

Incident Management

Incidents are interruptions or failure to services and assets and need to be addressed quickly so as to ensure that the impact to business operations are minimized. SIMAINTIC allows users to log incidents either through the Web Interface provided or by sending a mail to the configured help desk email. Incidents are reviewed and further categorized based on Priority / Severity , Category, Subcategory that is defined as part of the set-up.

Tickets can be assigned to team members based on attributes such as workload, specialization, location of work etc. Incidents progress through various states in the workflow till they are resolved and closed.If there are any Service Level agreement specified, the same can also be tracked using the System

<< Incident Workflow >>

Problem management

Problem Management deals with diagnosing the underlying cause of the incidents and, ultimately, to identify a means to remove that cause.

While Incident management deals with restoring the Interrupted Service as soon as possible, the Problem management process is applied to those incidents that have significant impact or occur repeatedly.

The First activity of the Problem Management process is to perform the Root Cause Analysis (RCA) investigate the problem and validate any work around. Once the Workarounds are identified, the Problem and the associated workarounds are stored in the database as Known Error database

After the workaround is identified, the next step would be to look at permanent resolution to the Problem. This may involve change to one or more Configurable items. The output in such case would be request for Change / application of the bug fix process.

<< Problem management process >>

Change Management

Change Management process deals with rolling out and prioritizing changes efficiently, without negatively impacting customers or agreed-upon service levels. The Change Management process stems from the business need of
i. Providing a stable, reliable and predictable process ii. Ability to change rapidly to meet the evolving business need

In line with the above need, SIMAINTIC has defined the Change Management process that can help the Users to Implement the Change in a systematic manner. In order to ensure that the flexible, there are multiple workflows that are provided for managing the change.
1. Normal / Planned Change - Process defined to execute planned changes.
2. Emergency Change Management - Process defined to handle emergency Changes that get originated
3. Standard Changes - These changes are routine in nature and do not need any specific approval to implement

In order to make the Change Management process more efficient, the system provides standard workflows that can be used for handling the routine changes that are similar to past changes. For changes that are different from Past changes, the system provides a easy to configure Workflow engine that can be used to create new Change Models that standardizes the procedure for implementing such changes.

<< Normal / Planned Change workflow >>

<< Emergency Change Request >>

<< Standard Change Requests >>

Release Management

Release Management is the process responsible for planning, scheduling, and controlling the build, in addition to testing and deploying Releases. Release Management ensures delivery of new and enhanced IT services required by the business, while protecting the integrity of existing services.

<< Release Management >>

Bug Fix Managment

Bug Fix management is the process responsible for fixing all the Defects that have been reported. The process ensures that the defects go through a proper stages of Analysis , Fix, Testing before it is deployed in production.

<< Bug Fix management >>

Service Request Management

Service Requests that are raised by the users need to be addressed in a timely manner. SIMAINTIC allows Users to log in Service Requests that can be reviewed and assigned by the Support manager to the appropriate team member. SIMAINTIC comes with a well defined Service Request management process. Services can be of varying kinds like request for information, documentation or requests for IT services or hardware and software.

<< Service Requests >>

Workflow Catalogue

SIMAINTIC provides enormous flexibility for the process workflows to be configured based on organizational processes. While there are standard built-in workflows for handling different classification of tickets such as incidents, service request, etc. new workflows for different types of services can be quickly created. These can be used to manage non IT business processes too.

The flexible Workflow engine can be used to develop different workflows and navigation from one workflow to another workflow during ticket resolution can be achieved seamlessly.

SIMAINTIC also provides the capability to define parent child relationships between tickets which allows dependencies to be mapped and tracked. This is useful in cases where there may be multiple activities with different owners or workgroups which have to be completed before the primary ticket can be closed.

Why SIMAINTIC:

  • Improved Efficiency and reduced Operational Cost
  • Self Help efficiency and Workload reduction
  • Improved visibility into Operations & Performance
  • Increased Control and Governance
  • Better Service / Customer experience
  • Opportunity for improvement
  • Improved Access / Communication Channels & Effective Communication
  • Standardization of processes
  • Improved Collaboration between different teams