Lubricant Usage Management System for Cement Plant

Designed a Usage management system for Lubricant consumption for all equipment in a Cement Plant. The system is designed to control inventory, use and misuse, equipment wise lubrication history, service alerts, business intelligence for lube ordering, machine consumptions and performance.

When the project was awarded to us we created a web based comprehensive management system. The system managed complete track of lubricant inventory and equipment tracking of company assets that utilized the lubricants. The system maintains the details related to equipment wise lubricant usage.

The system maintains a scheduler that keeps track of scheduled deliveries of lubricants complete with grade, type of lubricants, the maintenance cycle required. Automatic alert and delivery dispatch ticket is generated for each maintenance job that is due.

With each dispatch the system requires the users to enter the amount released and used. With each data update the system stores vast amount of information that is churned by an intelligent reporting tool that provides insights about the amount of usage and how you can optimize the lubricant usage to lower maintenance costs. Advanced search allows users to keep track on the inventory and automatic alerts prompts the users to raise Purchase orders when the stock reaches reorder level. Stock tracking report provides an insight into the exact stock at hand.

Goods distribution module allows the users to transfer stock in between departments. Some of the direct benefits the implementation offers comprise of Reduction in the number of maintenance service calls on the machine through implementation of timely service schedules, reduction in Lube inventory & wastages. The reporting tool provides MIS for machine requiring maintenance based on additional lube top ups required and MIS for reordering reducing the human involvement and cost of operations.

Background

The existing manual system for management of lubricant usage across the cement plant provided no control over inventory, the stock operators had no insights into the use and misuse of lubricants nor did they have details related to equipment wise lubrication history. They had to manually keep tab on inventory offer foreseeing the need to reorder fast moving goods that lead to delays in services.

The client wanted a system that:

Could automate the complete usage management
Keep a tab on the services required by the equipments
Alert the stakeholders when next service was impending
Provide exact insight into inventory and alert when the goods reached reorder level
Reporting tool that could generate reports for use and misuse, equipment

Solution

The client collaborated with Cygnet Infotech to deliver a system that was designed using .Net platform.

This web based comprehensive management system keeps complete track of lubricant inventory and equipment. A scheduling tool allows the users to define the service patterns for each equipment and type of lubricant to be used for each service.

Whenever the next service is due automatic alerts are sent to the designated people and users are required to enter the exact consumption against the amount despatched. With each dispatch the system requires the users to enter the amount released and used. With each data update the system stores vast amount of information that is churned by an intelligent reporting tool that provides insights about the amount of usage and how you can optimize the lubricant usage to lower maintenance costs.

Advanced search allows users to keep track on the inventory and automatic alerts prompts the users to raise Purchase orders when the stock reaches reorder level. Stock tracking report provides an insight into the exact stock as well as providing an insight into fast moving and slow moving goods.

The users can also view the list of lubricants that are used lowest and hence accordingly plan the purchase ensuring no money blockages. A Goods distribution module allows the users to transfer stock in between departments and keep a tab on transferred inventory.

The system has an exhaustive reporting tool that allows an insight into details such as machines requiring maintenance and frequency of maintenance, Usage of lubricants and reorder.

The system provides an intelligent lubricant usage tracking system that has helped the management make informed business decisions that have reduced company costs and optimized lubricant usage.

Technology Highlights

Software/ Tools	Dot Net Framework 3.5,.Net
Back End	MSSQL 2005

Benefits to the client

Reduced the no. of maintenance service calls on the machine through implementation of timely service schedules
Reduced Lube inventory & wastages
Reporting tool that provides accurate data related to usage and consumption