This is where Trapo began. One of us worked at a 6,000-trap facility that decided (correctly) to replace all of their traps after a decade of neglecting maintenance. As a steamfitter with 20 years experience, he is a poor typist. But his job was to prepare work orders for a contractor to replace all 6,000 traps. Also, he had to stay within a budget. He asked, "Can you write a little program to help?" We did. It grew.
If your facility runs with work orders (most do) and you have more than a few traps, you need this Stage. Clerical personnel and secretaries can run it, as it orders most parts automatically and checks whether the other parts are appropriate. The ease, quickness and accuracy of preparing trap maintenance work orders will quickly repay its cost.
Trap replacement work orders, many automatic features for preparation
The work orders are organized by building (although it can be called something else). Information is printed on each trap -- size, type, pressure, location, etc. The work order is separated into trap work, asbestos abatement, relagging, and miscellaneous, although you can combine trap and relagging work if you wish..
Trapo can simultaneously add a trap to the database and order it replaced. You can also order such parts as a test-tee and valve, isolation valves, check valves, and strainers. A single key press orders the trap or any of these parts. Then, you can copy the trap data and ordered work to another trap. Using this, one steamfitter input trap data and prepared work orders to replace 700 traps in three days, not including data collection time. This was almost an inch of paper describing $150,000 of work.
Parts lists by building and groups of buildings
Parts lists are automatically prepared by building. Also, if you are working on a group of smaller "buildings" (manholes, for instance), they can be combined into a single work order. For this, a parts list is printed for each "building" and for the overall work order. This helps you get the right parts to the right place. The parts list can also be printed to disk for communication with a general-purpose maintenance management system.
Automatically prepared when a trap is marked bad on the trap check list
Combining trap testing with Trapo's automatic work order features makes replacing bad traps even easier. When one is marked bad on the trap check list, its replacement is automatically ordered and placed in a work order. Then, you decide when to issue the work order.
Accounting feature enforces any cost and item budgets
All of us have to stay within budgets. Trapo won't let you print a work order if it will violate a budget. You can set budgets for unit cost, total cost, and for individual parts (plus or minus any percent). Trapo will enforce all of these at the same time.
Maintain spare parts inventory for trap replacement
The tracking of individual parts can also be used to maintain a spare parts inventory for trap maintenance. Again, if you are using this, you can't order work requiring parts that are not in inventory.
Complete cost/benefit analysis of potential trap replacements
Trapo includes a cost/benefit analysis with each work order printout. This makes it clear to management that the maintenance needs to be done.
Selected traps can have automatically-ordered replacements
Trap selection has special uses here, too. You can order replacements automatically for Selected traps. For example, one facility received almost 200 bad traps from a manufacturer. In a few months, they began to fail. The manufacturer supplied replacements, but work orders had to be prepared - it took five minutes, mostly for printing.
Stage IVa - Asbestos Work Orders
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