In process operations that typically run 24/7, planning for scheduled shutdowns depends on the ability to identify functionally related equipment and ensure that all tasks for that equipment are consolidated on the shutdown schedule. To reduce overtime costs, the shutdown plan must also include effective deployment of technicians and contractors.

4Site solutions for shutdown planning provide the robust component/equipment hierarchy description, labor availability data and effective project plans that help you minimize impact on production even when critical equipment and processes are involved.

The pulp and paper industry has an enviable record for efficient energy use, partially due to cogeneration and heat recovery systems, and yet total consumption is greater than 10% of total manufacturing energy use in the U.S. With this level of demand for energy, the industry has no choice but to continue its drive for even greater reductions in consumption. To ensure viability smaller operations that lack the capital resources for replacement technology must look to efficiencies within their current plant configuration. Equipment optimization, quality spare parts and well-designed maintenance procedures can help to achieve those efficiencies.

Process industries typically have centralized operations as well as remote installations. This distribution of activities presents its own challenges as timely data must be gathered from all facets of the operation to give an accurate overall picture.

4Site’s integrated, browser based mobile solutions run via browser on mobile wireless devices such as Pocket PCs to help you get the job done wherever you are. Increased productivity, reduced travel and response times and improved maintenance strategies supported by increased data accuracy are all available.

Equipment reliability is a priority for process industries where unplanned stoppages in critical areas can affect the entire production. Well-maintained equipment contributes to both sides of the profitability equation – cost savings and increased earnings. Using effective preventive maintenance plans as part of a CMMS solution, you can reduce costs by extending asset life and also build earnings by increasing plant utilization and product quality. 4Site's economical software solutions give you the tools to maximize plant capacity while ensuring production quality.

Developing preventive maintenance plans depends on collecting the right data and turning that raw data into actionable tasks. Knowing when to execute a maintenance task on location or when to remove equipment for overhaul or replacement requires a careful balancing of the cost of maintenance against the cost of failure. To identify failure risks and support repair or replace decisions, 4Site offers real time asset performance, failure and root cause analysis tools developed over decades of providing solutions to process industries.

Planned and preventive maintenance coupled with effective spare parts management can significantly reduce both the frequency of repair and cost of replacement. Replacing low cost consumables before expensive components are damaged isn’t a tough decision, but identifying the relationships between components can be a challenge unless you have access to comprehensive equipment and work order history.

A complete picture of usage and failure patterns can help reduce material costs. Knowing what is needed and when, you can move from just-in-case to just-in-time levels of parts stocking. You dramatically reduce the occurrence of emergency acquisitions so you move from fastest availability and shipping, to lowest cost, best quality and consolidated freight.

Cyclic markets are a predictable feature of many resource based industries such as steel production, pulp and paper, and mining. Add in the expanding regulatory requirements, as well as consumer and environmental interests promoting change, and these industries must be capable of rapid and informed responses.

4Site’s designed-in flexibility, scalability and easy customization have helped many organizations manage new equipment configurations, emerging technologies and turbulence in the marketplace.