The development and production of wheelsets requires special knowledge, experience and constant self-improvement. The company’s expertise has been developed over many decades and cannot be easily transferred or imitated. It is at the core of their service. They see the production of wheels and wheelsets as a “running” process with many changes and challenges. Their internal engine is an innovative approach that helps them keep their products at the cutting edge within the industry.
Problems from the past:
- Lack of a tool to evaluate production data collection based on real-time hard data with chronological traceability.
- Difficult to evaluate the effectiveness of human resources.
- Complicated maintenance management of a large machinery fleet.
- Reduced clarity of maintenance planning.
- Difficult access for maintenance personnel to review spare parts of the equipment being repaired.
PM Toolkit and iWi implementation process:
- The PMT pilot was implemented on the wheel line with automatic handling, the rollout was sequentially implemented across all machining and assembly line operations.
- Specific requirements for integration with PMT, PIS and IFS.
- Migration of DB PMT to Oracle.
- Implementation of iWi web maintenance management for the pilot line.
- Deployment of the iWi mobile app.
- Rollout iWi.
Benefits of PMT:
- Thanks to its in-depth knowledge of machines and their control systems, GHH-Bonatrans records signals to identify productive and unproductive production times.
- Detailed and clear statistical analysis of individual production phases allows them to focus on improving the efficiency of production equipment, increasing labour productivity and ultimately optimising time consumption standards.
- Historically comparable data available for further analysis.
- In addition to an overview of production and downtime, the PMToolkit also records the working time of operators on individual machines. Worklogs (records of operator work) are further used to calculate wages.
- The visualisations in the app and on the LED screens are both informative and motivational.
Benefits of iWi:
- Digitization of all maintenance requests with access from the web environment.
- Streamlining the maintenance management process.
- Overview of all maintenance work performed by maintenance staff and realistic reports on staff utilisation.
- Overview of compatible spare parts for the device being repaired directly from the iWi app.
- Upload photos to your order directly from the iWi app.
- Documentation available from the iWi app.
- Device repair history available from the iWi app.
- An overview of all remaining maintenance contracts with their colour resolution and prioritisation.
- Scheduling preventive maintenance down to the level of individual activities for employees.
- Checklists for maintenance contract.
- Data transfer to IFS for evaluation of maintenance costs.
The innovative PM Toolkit and iWi tools serve GHH-Bonatrans for continuous improvement and are already an integral part of their work tools.
Customer statement:
Miroslav Svoboda
Industrial Engineer Bonatrans Group, a.s.
"For quality management you need quality data." "We don't need to keep track of people at work, we just need to keep track of machines at work."
