The ERP.Repair module is designed for the organization of the operating
process of a company providing repair and maintenance services. It is a
computerized maintenance management system (CMMS).
Solutions of the CMMS category support
the following functionalities:
• The maintenance of the equipment
database including the frequency and scope of repairs;
• Information about spare parts;
• Information about maintenance
• Drawing up spare part purchase orders
and job orders in accordance with the database containing the standards
• Calendar planning of maintenance and
• Aggregation and storage of cost data
for further analysis;
• Aggregation and storage of data about
events (failures, emergencies) for further analysis;
• Standard and extended maintenance and
• And many others.
Even before a vessel has reached the
dock or a piece of equipment has arrived to the repair shop, the
documents necessary for workers to come to the site are registered in the
system: the contract, the list of jobs, requirements for the job, the
preliminary assessment of the company’s income and expenses in relation
to this order. The characteristic feature of the module is the fast
compilation of the price quotation and the data concerning a new order on
the basis of a similar external order created earlier.
The order goes through certain stages
of preliminary processing: the pricing of jobs for the order is
performed, the employees’ salary is determined (specialists from the
preproduction department who establish the employees’ salary and the
composition of materials are involved in the order processing). The
marginal revenue for each type of works is calculated on the basis of the
planning inventory data entered into the system. As it is not only the
employees of the factory that are involved in the performance of works
but also third-party organizations, there is an option for timely
entering of the information concerning the performance of works by
contractors into the system.
Material requirements planning allows
the needs for all materials and components to be calculated for putting
an order into production, taking into account warehouse stocks as well as
scheduled receipts and shipments. The above needs are based on sales
orders, shop orders and job orders (repairs). The information is checked
against nonredundant stocks, supply orders and shop orders to determine
needs for materials and components. In addition, data concerning
independent demand, for instance, forecast demand for spare parts, can be
taken into account.
The purpose of capacity requirements
planning is to determine realistic timeframes for production target
delivery using the available capacity. The planning of work centre load
simplifies the process of identifying potential bottlenecks and allows
the underutilization and overloading of production capacities and
personnel to be evened out.
During the performance of repairs, the scope of the works to be completed may undergo major
changes: adjustments are made in the course of the expert review of the
vessel or piece of equipment for failure as well as assembly and
disassembly of the equipment declared for repairs. In the course of
repairs, the actual costs can change multi-fold compared to those
established in the repair standards. Records of expert reviews for
failure are executed by production engineers, and this operation is
completed directly in the system.
The employees responsible for the
monitoring of material issue check the figures estimated by production
engineers against the actual figures of the consumption of materials. The
system supports the recording of arbitrary sets of calculation items, the
recording of resource price catalogues, the recording of various methods
of calculation of overhead costs (on the basis of shares of other items,
cost estimates or various allocation bases) and runs the necessary
reporting, allowing the operational monitoring of the production process
without having to wait for the completion of all the works and for the
vessel to leave the dock.
The order manager analyses the obtained
information (the economist in charge of the order is also involved in the
analysis), monitors the progress of the order and identifies the reasons
and sources of overspending. On the basis of the data concerning planned
and actual costs, the manager can adjust the prices of certain jobs while
being able to give sufficient rationale to the customer. The quality
control department is involved in the process at the stage of the
delivery of works, drawing up the work certificate of the completion of a
certain work type in the system.
The information about performed works
is used by economists, accountants and managers of the order. At the same
time, the employees of the contract administration receive information
about the execution of contracts.