Nanchang Shuanggang Water Supply Company Limited achieves paperless maintenance with Coswin and bluebee®
Nanchang Shuanggang Water Supply Company Limited
With support from the People’s Government of Nanchang and the Changbei Economic and Technical Development Zone, Nanchang Shuanggang Water Supply Company Limited was established in 1996. The company is dedicated to the provision of quality water services to residents and customers in the Changbei Economic & Technical Development Zone.
In June 2008, the first expanded construction segment commenced operations, increasing capacity from the original 70,000 m3/d to the 100,000 m3/d. The project included the newly built raw water pumping station, the installation of a 1.2×4000 (m) raw water pipeline and a 30,000 m3/d water clarifying system made up of one horizontal flow tank, four filtration tanks and a clarifying tank, serving 160,000 residents.
A strong emphasis is placed on efficient management in operations. Strict monitoring is also applied to enhance the quality of the water. The qualification rate currently stands at 100%. Besides, the company is proactive in its implementation of power-saving measures. The rate of power consumption today is 10% lower than what it was prior to the establishment of the company.
Project introduction
The project draws on Siveco’s long water treatment experience and a mature “Core Model” based on the ISO 55000 Asset Management standard (and its Chinese equivalent GB/T 33172).
Unlike traditional CMMS, this project is dominated by the use of the bluebee® mobile solution. In the initial stage, the General Manager of Nanchang Shuanggang Water Supply emphasized that he hoped to abandon the traditional maintenance management model. Coswin and the plant automation center serve together as the central dispatching station, while execution and feedback of the work are directly performed on mobiles.
Project objectives
Based on discussions before the project, Siveco implemented the “maintenance improvement project” in Nanchang Shuanggang Water Supply, establishing concepts, systems and practices to achieve the following goals:
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Taking the ISO 55000 asset management standard as the guiding principle, establish advanced maintenance management concepts and methods.
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Set up a database of all technical assets, providing a solid foundation for the company’s maintenance and management system.
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Use bluebee® for inspection management.
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Ensure all maintenance operations can be recorded and used for analysis.
The Siveco project
This maintenance management project was officially launched on November 25, 2015, based on Coswin and bluebee®. The Siveco team arrived at Nanchang Shuanggang Water Supply on November 25, 2015. The Siveco team held a kick-off meeting with the core team of Nanchang Shuanggang Water Supply and introduced the core document framework of Siveco’s best practices for intelligent water treatment projects. During this period, the two sides conducted in-depth discussions.
Based on Siveco’s abundant water plants’ implementation experience and the customized requirements of Nanchang Shuanggang Water Supply, the following implementation plan was determined:
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Establish plant structure and equipment list based on relevant international standards, mainly involving the introduction of equipment types and equipment criticality management methods to the existing database and experience, starting from already documented main equipment and gradually expanding to the whole plant.
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Based on the “Core Model”, establish SDCA (Symptoms, Failures, Causes and Measures) codes for work order records and the corresponding analysis system.
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Use bluebee® to schedule and execute all inspection plans, with a focus on plan completion and work order records. After ensuring its completion, the plan is optimized by systematic analysis of the results to make it more efficient.
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Apply standard report package designed based on EU standard EN 15341 – Maintenance key performance indicators and past successful experience of Siveco in similar plants.
The “Core Model” is Siveco’s strategy for the implementation of maintenance management for Nanchang Shuanggang Water Supply, according to its production type. Direct application of the “Core Model” ensures the quality of the project and its alignment with quick business results. The “Core Model” covers:
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Equipment structures and coding
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Work processes
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Preventive maintenance
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Inspections
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Key Performance Indicators
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System implementation strategy
Coswin was installed on a central server; both engineers and management teams access the system through the internal network. A complete and updatable technical database was established in the system, covering equipment and spare parts data, failure information, preventive maintenance plans, etc., to support engineers’ daily maintenance work analysis. By systematically recording failures and preventive or corrective work, users gradually establish a maintenance history database to support various technical and management analysis. The bottom-up data system ultimately supports management’s various financial or technical decisions and long-term improvement strategies.
Project results
According to Tang Hui, General Manager of Nanchang Shuanggang Water Supply:
“I think that the Core Model discussed by Siveco and our group technical department is the key condition for the success of CMMS in our company. At the same time, the bluebee® mobile solution fits very well our requirements for the setup of smart water plants. Of course, Siveco’s first-class expertise in equipment management is another key factor in the successful deployment of Coswin.”
“I think that the Core Model discussed by Siveco and our group technical department is the key condition for the success of CMMS in our company. At the same time, the bluebee® mobile solution fits very well our requirements for the setup of smart water plants. Of course, Siveco’s first-class expertise in equipment management is another key factor in the successful deployment of Coswin.”
After the implementation of this project, Nanchang Shuanggang Water Supply’s operation and maintenance activities including daily inspections, preventive maintenance, corrective maintenance and production inspections are performed with the bluebee® mobile solution. All the preventive maintenance and inspection work orders are automatically sent to the person in charge after generation by Coswin, ensuring timely and effective execution with bluebee®. In daily operation, if any equipment failure is detected, a repair order (including pictures, video and other information) can be directly created in bluebee®. The order is then transmitted to Coswin. The central control room staff can view all information in real-time on the big screen. The engineer will assign work to technicians based on skills, historical records and preliminary judgment of work experience. Workers receive work orders on their mobile, execute according to instructions and provide feedback.
The new smart process completely gets rid of the traditional “paper, pen and computer input” model. Technical work can now be managed efficiently and visually, with a focus on improvement instead of administration.
To ensure the continuous improvement of system usage, Siveco conducts onsite audit once a year. Figures obtained during the last audit conducted at the end of 2017 shows that a comprehensive asset database has been established: 100% of critical equipment are documented, in line with corporate requirements and good practices. Statistics also show that work orders have received comprehensive feedback, including failure information for breakdowns and time records for 99% of the work orders. These verifiable, audited, figures prove that the project goals were achieved.
In terms of IT security, all communication between the mobiles and the back-end database is performed through VPN, ensuring high level of data security. This comes in addition to the other security features of bluebee®: dedicated app, registration of device ID in the central system, login and password, central device monitoring and data synchronization gateway (bluebee® sync) and firewall.
Future developments
According to the results of the 2016 and 2017 audits, Nanchang Shuanggang Water Supply is planning to incorporate spare parts management into the CMMS system: by tracking spare parts consumption and conducting detailed analysis from the perspective of asset management (not only from a finance and admin perspective), the company aims to achieve effective inventory control and to further optimize its operational costs.
