Lifecycle control of replaceable equipment parts at a metallurgical enterprise

Mallenom Systems successfully completed the development and implementation of an information system for tracking the lifecycle and operating time of replaceable parts of metallurgical equipment and forecasting their major repairs.

The customer required monitoring of the condition of equipment and its replaceable parts at several production units, as well as creation and approval of requests/reports for repairs.

Project objectives:

• improving control over equipment condition for timely repairs and reducing the risk of producing non-conforming products
• recording the volume of repair work
• tracking the complete lifecycle of equipment
• forecasting dates of major repairs

Solution:

The developed information system (IS) calculates the durability of replaceable parts installed in production units. Analytical screens and graphs with data on the complete lifecycle of equipment and its elements in retrospect, forecasted dates of major repair, and durability indication are available to the user.

The work was carried out in three stages:

• Identification of key effects from IS implementation, analysis of source data, IS architecture design
• Software development, GUI creation, integration with external systems, preliminary testing
• Pilot industrial operation of the IS, testing, documentation preparation and system handover to support

Results include placement of source code in GitLab, CI/CD configuration, successful implementation on the Customer's infrastructure and preparation for expansion to other shops.

Key benefits that the customer received from the IS implementation:

• Increased efficiency of control and management through timely detection of changes and accurate repair planning
• Cost reduction and optimization of repair works through automated tracking of equipment lifecycle
• Improved planning and forecasting of repairs to reduce unplanned downtime
• Complete transparency through dashboards and metrics for quick response to problems
• Automation of data collection and analytics to improve information accuracy and accelerate decisions
• Ability to quickly expand the system to other production areas
• Implementation of new approaches to equipment lifecycle management to increase competitiveness

Overall, the implemented system provides more efficient, transparent and predictable equipment management, which contributes to cost reduction, improved product quality and strengthening of the company's market position.