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ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
ARMS Reliability Corporate Brochure
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ARMS Reliability Corporate Brochure

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ARMS Reliability is a service, training and software organisation providing a “one stop shop” for Reliability Engineering, RAMS and Maintenance Optimization for both new and existing projects. Our aim …

ARMS Reliability is a service, training and software organisation providing a “one stop shop” for Reliability Engineering, RAMS and Maintenance Optimization for both new and existing projects. Our aim is to empower our clients with the knowledge and

expertise to make asset management decisions,that optimize plant maintenance, reliability and availability at the lowest cost and risk.

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  • 1. THESE THREE kEy ELEMENTS dRIvE THE ARMS RELIAbILITy bUSINESS. Empowering our clients to make better decisions underpins our training, our services and our software. It provides our clients with the means to adapt new methods and enhance their core competency. It goes beyond the training room – empowerment is about learning and applying new methods, then measuring outcomes and seeking opportunities for continuous improvement. At ARMS Reliability we value learning as a lifelong assets to business performance. They can process. Learning is dynamic with different make proactive decisions and achieve asset needs determining the best pathway to growth. management goals. Our education pathways include skill-based training, workshops, pilot studies, project The ARMS reliability history is deeply rooted support, advanced skill training, mentoring, in mining, manufacturing, power and utilities. auditing and user group networks. ARMS These industries have recognised that reliability, Reliability students come from all levels: availability, maintainability and safety are cost- experienced technicians, engineers, critical at all stages of a project lifecycle. They managers, project managers and subject see the value of building reliability into design matter experts. Our teachers are as early as possible and of installing continuous experts too, who facilitate the learning improvement processes into existing operations. process through a range of flexible Empowered, educated and equipped … they are delivery styles. ready to meet the special challenges of their Equipped with powerful software individual business environments. tools and the capacity to make data-based decisions, our clients can optimise the contribution of2
  • 2. People ClientsThe passion and drive of our people to be Many of ARMS Reliability’s clients are longexperts and apply their knowledge to the field term. Our most powerful marketing tool isof Reliability is reflected in the enthusiastic client referral, making satisfied customerssupport we engender in our clients. critical to our future. We manage client relationships mindfully,Partners providing excellent service, efficiently, with integrity, and listening to feedback so we canARMS Reliability’s business relationship with continue to improve.Isograph stretches back to 1997. During thattime we have regularly contributed to thedevelopment of the Availability Workbenchsuite. Isograph recognises ARMS Reliabilityas experts in training and implementation ofthe RCM and System Availability simulationmodules.We have also maintained our relationship withApollo Associates since 1997 for the deliveryof Apollo Root Cause Analysis. TeachingApollo regularly is a true privilege that ismirrored by students’ realisation that they cananalyse and solve problems of any complexitywith a simple four-step method. 3
  • 3. ARMS RELIABILITYOur Leadership PEOPLE, PARTNERS ANd CLIENTSMichael Drew - Managing DirectorJason Apps - Technical Director The ARMS Reliability team are experienced practitionersDarren Gloster - VP North America and experts in reliability and root cause analysis. The business was founded on a passionate desire to empower other companies to move away from reac-Our Team tive behaviours, recognising that technical solutionsErick Alingcastre Peter Horsburgh alone do not drive this transition. This premise hasMark Arbuthnot Jack JagerJason Ballentine Andrew Blunden remained unchanged since we commencedCraig Brydges Ned Callahan operation in 1995.Brian Connors Allan FoxBrian Heinsius Leigh JarmanJulien Maffre Thomas Reddell Our goal is to perform on as wide a field as possi-Rex Tomlins Stuart Tupper ble whilst maintaining our reputation for serviceLes Gibson Peter KyselicaGreg Morphet Bob DiFrancesco excellence.Dennis French Paul DaugalisCustomer Service TeamJohn McIntosh Kelly HickmanTony Nye Paula-Jo MitchellMelanie Watkins 4
  • 4. LEADERSHIP TEAM What we offer Software ARMS Reliability is a services, The Isograph range is one of the most extensive available. One reason training and software organisation it continues to be an industry leader is the simplicity of use it affords, specialising in reliability analysis enabling the user to carry out otherwise complex analysis. and cause analysis for both new and The joy for the ARMS Reliability Team in the teaching and implementation existing projects. of the Isograph suite is that using the RAMS software is intuitive, and leads to powerful decisions based on sound logic. While Reliability concepts Our areas of expertise include: may seem complicated and challenging, the Isograph tools equip the user to embrace the concepts with confidence and to use them to arrive at > Reliability Centred Maintenance: decisions without getting bogged down in mathematical complexity. introductory and advanced training, software, facilitation, project completion. Training ARMS Reliability has been delivering Reliability Training since 1995. > System Availability Modeling: We prefer delivering experiential training because we know it provides introductory and advanced the most enduring learning. It is also most enjoyed by participants and training, software, therefore more engaging. Our well-defined course materials cover a wide project completion. cross-section of subject matter in the field of Reliability. We take particular > Integrating Reliability with SAP, pride in teaching reliability concepts across a broad range of roles, Maximo, Ellipse: implementation, including managers, engineers, technicians and subject matter experts. configuration, training. > Root Cause Analysis: training, Services software, facilitation, incident Because we are expert practitioners, we can train effectively and continue investigation. to provide direction for software development. We love to undertake and complete projects and to see our clients achieving brilliant outcomes for their enterprises. 5
  • 5. THE ARMS IFFER ENCE IABIL ITY D REL ARMS Reliability provides a “one stop shop” for Reliability programs, for both new and existing projects. We have proven success on RAMS studies for significant new projects where our Reliability experts develop whole-of-project models including design verification, maintenance plan optimisation, budget forecast, risk evaluation, resource requirements, auto loading plans and matching technical work plans to Asset Management Systems. ARMS Reliability provides a “one stop shop” for regular failures, low availability levels, or high costs of Reliability programs, for both new and existing projects. maintenance. For us it’s a challenge, for our clients it We have proven success on RAMS studies for significant often means millions of dollars impact to their bottom new projects where our Reliability experts develop line. Increasingly, we are being asked to perform whole-of-project models including design verification, RAMS studies at the preliminary design stage of major maintenance plan optimisation, budget forecast, projects. This allows us to build lifecycle models that risk evaluation, resource requirements, auto loading support proactive reliability, and ensure that asset plans and matching technical work plans to Asset management systems are set up appropriately with Management Systems. plans, task instructions, reporting codes and good functional hierarchies. Our ability to model real world asset performance and identify optimal maintenance and logistics It also enables meaningful performance measures to arrangements has been employed by utilities, rail and be defined to enable targets and thresholds to be set, power generators to improve asset management and alerting asset performance managers of deviations demonstrate improvements to owners, regulators and before the asset falls into reactive maintenance mode. internal stakeholders. Our people love the challenge of turning around plant that is not performing due to6
  • 6. Our Clients Our clients come in all shapesKey Differentiators and sizes and from a diverseWhat differentiates ARMS Reliability from other Reliability range of industries andservice providers? disciplines.> People who are experienced, qualified, passionate and highly expert in Reliability methods. BHP Iron Ore Asset Reliability 2009-2010> Isograph software: The most powerful RAMS software tools on the market. BHP Potash Blair Athol Coal> Integration of RCM with Asset Management Systems: SAP, Maximo, Ellipse. BMA Coal> Efficient work methods proven over multiple clients and industries. BHP Illawarra Coal Collohausi> Knowledge availability through extensive libraries of failure data, and maintenance templates. Rasgas> Proven training excellence. Qatar Petroleum> Success in small and large project completion. Dalrymple Bay Coal Terminal Peabody Energy> Success built on long term customer relationships. Anglo Gold BHP Olympic Dam ExpansionWhat our clients say about us Alcoa“ Have engagedsuccessesour business globally with huge Business Improvement ARMS in through delivering reliability, Nyrstar Sydney Water productivity and safety “ SA Water Watercare“ In terms of Asset aReliability processesnot hesitate in engaging improvement, as business we would and business Brisbane Water “ ARMS as a partner Metro Water District Of Southern California“ TheofARMSsites where engaged. Withhas deliveredand the way ARMS all our team is professional and past results results across Snowy Hydro Portland General Electric conduct their business engaging our people, I would have no hesitation Avista recommending ARMS to others “ Vline Qld Rail“ My experience when using ARMS is that the ARMS team has delivered positive valued results at each site where engaged and in particular to a EDI Rail very high standard “ 7
  • 7. “ EMPOWERINgCLIENTS TO MAkEbETTER ASSET “dECISIONS.8
  • 8. SERVICES SERVICESARMS Reliability provides expert services in the followingareas, encompassing all phases of asset life cycle for bothnew and existing plants.We focus on empowering our clients with the knowledge and expertise to respond to criticalquestions about their plant performance across a full range of related disciplines.Root Cause Analysis Facilitation ARMS Reliability boasts a track record of success in partnering> How do I find the best solution to prevent an incident recurring? clients to achieve their design, maintenance and performance> How do I reduce systemic causes impacting defects? objectives. Our portfolio is cross-Incident Investigation platform and cross-industry,How do I investigate a major incident? including sizable and complex projects such as:RBD Simulation Modelling > Major expansion of iron ore> Will my design deliver production objectives? handling facility> Where are the critical bottlenecks which impact > Major expansion of coal handling production capacity? port facility> Will my maintenance plans support the Plant > Construction of greenfield Availability Target? alumina refinery> What level of spares is cost effective to hold? > Capital planning development for water and power utilitiesRCM Analysis > Assessment of maintenance plan> How do I develop maintenance plans for new for major hazardous facility equipment or existing equipment? chemical plant.> What Spares will I need? > Optimisation of maintenance plan of> What labor resources do I need? mining shovels and trucks> Maintenance plan Evaluation > Construction of mega-project to mine copper and uranium> Am I performing sufficient maintenance? > Evaluation of availability of large communications systems for land-based andMaintenance Plan Optimisation marine warning systems> How can I reduce maintenance costs? > Optimisation of maintenance plan of power> How can I improve reliability? generation> How can I improve availability? > Identification of “bad actors” of production> Capital Requirement Forecasting facility and facilitate solutions.> What capital do I need to budget over the > Development of zero-based budget for dairy industry next 10 years? > Development of libraries for templatingLife Cycle Cost Calculations a large utility.What is the total life cycle cost of this project intoday’s dollars? 9
  • 9. CASE STUDY: 1 Sydney Water – RCM and RBD Modeling Sydney Water is currently undertaking an The RCM modelling exercise will deliver the Sydney Water – RCM andfollowing features: Rbd Modeling enterprise-wide drive to create a sound, consistent and rational system on which it can confidently > capacity to identify, quantify and prioritise the base its business decisions. As a critical part of risks associated with equipment failures this initiative, Sydney Water has engaged ARMS Reliability to assist in building a reliability/ > standard sets of meaningful maintenance maintenance system that enables logical, auditable tasks that can be consistently applied across and justifiable business decisions related to relevant assets asset performance. The RBD modeling exercise will provide capacity to: This will be accomplished by creating RCM and RBD models of its critical Sewer Treatment Plants, > forecast availability system performance Sewer and Water Pump Stations. > quantify plant risks, such as environmental licence breaches. CASE STUDY: 2 Fonterra Edendale - Maintenance Strategy and Critical Item Review Fonterra Cooperative Group, New Zealand’s largest We also developed a reliability block diagram (RBD), company (by turnover), handles over a third of all providing criticality analysis of capacity and availability international dairy trade. during the design phase. In September 2009, it commissioned the world’s biggest The combination of the RCM-based maintenance milk dryer, capable of producing hundreds of tons of strategies and the RBD provided a quantitative analysis milk powder per day. platform from which capital and operational planning decisions continue to be made ARMS Reliability was engaged to provide a focused asset management approach to the new plant during the design and construction phase and developed all the RCM-based maintenance strategies ensuring that the asset was operated safely, risks and costs were minimised and production maximised.10
  • 10. EMPOWER EDUCATE EQUIPCASE STUDY: 3How Portland General Electric Used RCM to change their maintenance culturePortland General Electric (PGE) serves over 800,000 generator and an ammonia system. Each was selected tocustomers within a 4,000-square mile service area, including assist in the development of an optimised asset strategy52 Oregon cities. and to promote the benefits of RCM in achieving proactive maintenance.In 2006, PGE undertook a program to shift its maintenanceculture and to create a culture of proactivity. The culture change is an ongoing process but with the solid commitment of all stakeholders, it is achieving its goal.Using facilitated RCM studies and training, ARMS Reliabilityengaged with key stakeholders from PGE including a smallgroup of employees who undertook a 3 day intensive trainingworkshop.The workshop centred on the RCM method of maintenancetask optimisation. The participants learned about the use offailure data analysis and forecasting that reduce the coststo their business. This was the first step in promoting aproactive maintenance culture.The results of a series of brief RCM studies at different PGEgenerating sites were presented to the plant managers andwhile impressive per se, they particularly enabled promotionof the benefits of a proactive maintenance culture.The argument that “RCM will not work here” or “proactivemaintenance is not for us” can no longer be sustained.Since the initial studies, PGE has conducted others on aboiler feedwater system, a circulating cooling water system,a hydro generating power train, a heat recovery steam 11
  • 11. “ INTERACTIvE, HANdS ON, PRACTICAL TRAININg TO EdUCATE “ RELIAbILITy TEAMS.12
  • 12. TRAININGFor over 10 years industry has trusted ARMS Reliability tohelp improve the skills, knowledge and expertise of their human resources. ARMS Reliability delivers practical, hands-on courses to help you learn how to implement a wide variety of Reliability, Availability, Maintainability TRAINING and Safety (RAMS) methodologies into your organisation. Our courses are interactive and our teaching approach is to promote learning by experience. Students leave our training courses empowered with confidence, educated with valuable insights and equipped for effective decision making to reduce risk and maximise the reliability and availability of their assets. We offer training courses through either public or in-house delivery in the following subjects: > Reliability Centred Maintenance > System Availability Analysis > Root Cause Analysis > FaultTree Analysis > RAMS Analysis > Reliability Methods > Plant Modelling > Hazop Studies > Incident Investigation > CMRP Exams > Implementing your RCM > Life Cycle Costing or RCA program > Reliability Excellence 13
  • 13. Who should attend ARMS Reliability training? Design Engineers … who are looking to Maintenance Practitioners … who are use reliability analysis tools to improve the looking to introduce an effective continuous reliability of design. improvement strategy and involve the workforce in improved decision Asset Managers … who are looking to set making methods. up their work management system in a way that provides for continuous performance Safety Managers … who need to investigate improvement over the life of an asset incidents, reduce the risk of injury and or plant. improve workplace safety. Reliability Managers … who are looking to General Managers, CEOs and Executives … improve the performance of their assets who want to understand how to maximise whilst ensuring efficient use of resources. business performance, increase output, and improve organisational profits and Maintenance Planners … who need to shareholder value. improve maintenance plans and resource arrangements. Risk Managers … who need to optimise activities against the risk of failure and catastrophic incidents.14
  • 14. PROBLEM SOLVINGCourse Title Features and details Who Should Attend Duration Delivery mode and Class MaximumRCA 101e fundamentals of Apollo those seeking 2 hours online problem solving refresher training orApollo eRCA located in remote areas computer-based training course, with registrants receiving 12 months online access to course materialsRCA 102 provides the knowledge and skills operators, maintainers, 1 day / 25 max. public or necessary to effectively utilise safety representatives in-houseApollo RCA RCA and participate in problemParticipant analysisCourse developed to equip anyone who might participate in an accident investigation, or who needs to become a better problem solver (but will not be asked to facilitate an investigation)RCA 201 beneficial for anyone whose job engineers, planners, 2 day / 25 max. public or includes problem solving supervisors and lead in-houseApollo RCA personnelPractitioner all participants receive copy of (laptop anCourse Realitycharting software advantage)RCA 301 for facilitators with 6-12 months trained facilitators 1 day / 15 max. in-house experience; aimed at improvingApollo RCA skills in applying the method andSuper User ensuring successCourseRCA 401 for managers and supervisors not department managers, 0.5 Day / 15 max. in-house involved in the details of incident superintendents.Apollo RCA investigation, but having the needManagers to direct associated activitiesCourse course can also be used as an overview for anyone interested in effective problem solvingRCA 501 tracking corrective actions and those responsible 1 day in-house analysing failure data for effective failureFailure eliminationReportingII 101 basic incident investigation anyone required to 2 days public or management manage an incident in-houseIncidentInvestigation 15
  • 15. RELIABILITY TRAINING Course Title Features and details Who Should Attend Duration and Delivery mode Class Maximum REL 101 failure rates, FMEA, FMECA, RBD, RCM, FaultTrees, engineers who 1 day / 25 max. public or Reliability LCC, failure reporting require an overview of in-house Roadmap reliability methods REL 102 workshop with exercises illustrating how to move a anyone seeking a 2 days / 15 max. public or system from Reactive behavior to Proactive behavior more effective way to in-house Managing using Reliability Methods. make and integrate Reliability maintenance decisions Improvement covers introduction to Weibull Analysis, FMEA, RCM, RBD, and LCC. participants make decisions in a simulated environment, compare the benefits, and learn how to evaluate maintenance decisions against impacts. no computers required. participants download demo’ version of RCMCost and anyone interested in 2 days public RCM 101 learning how RCM are introduced to maintenance decision making using Managing RCM simulation software computer RCMCost. using RCMCost can assist them and demo’ participants receive booklet with typical reports out software of RCMCost, including a maintenance plan and work essential instructions. RCM 201 maintenance optimisation using RCM and life cycle RCM team 3 days / 12 max. in-house Maintenance simulation. members involved Optimisation in a maintenance computer skill-building course on how to use RCMCost: and licensed o Weibull data analysis. improvement study software o risk/cost benefits analysis. essential o maintenance task optimisation o plan development. RCM 301 advanced features that allow more accurate requires completion 2 days / 15 max. in-house ADV Software emulation of reality: of RCM 201 and computer Features and o hidden failures experience as an RCM and licensed Manipulation o redundancy factors team member software o operating time factor essential o risk and criticality o P-F distributions efficient use of RCMCost inputs and outputs: o data mapping o producing work instruction documents o scenario comparison. o maintenance cost prediction o safety criticality RBD 301 system analysis using Reliability Block Diagrams: team members, 2 days / 15 max. in-house Plant Availability o parallel and series dependencies process engineers, o redundancy maintenance engineers computer and Simulation o importance ranking, licensed o spares inventory holding software o “what if” scenario analysis essential RBD 401 Plant Capacity Determination: process engineers, 1 day / 15 max. in-house Advanced Plant o process flow analysis maintenance engineers computer and Availability o determining capacity licensed Simulation o identifying bottlenecks software o aligning shutdowns essential o “what if” scenario analysis o criticality analysis of complex systems LCC 401 life cycle costs calculation: project, plant 1 day / 15 max. in-house o cost tree development including sustaining and maintenance Life Cycle Cost and acquisition costs engineers, involved in computer and Calculations o time value of money asset selection and licensed o rate of return and alternative scenario repair or replacement software comparison decisions essential16
  • 16. Course Title Features and details Who Should Attend Duration Delivery mode and Class MaximumFTA 201 quantitative risk analysis using fault trees safety engineers, risk 2 days / 15 max. public andFault Tree and event trees: managers, instrumentation in-houseTraining o initiator events or control engineers computer o enabling events designing level of and demo’ o importance analysis protection. software o event tree essential o scenario analysisHAS 201 HASOP studies: team members involved in 1 day / 15 max. In-houseHazops o key words hazard assessment computer o setting criteria and licensed o risk matrix software o hasard ranking essentialREL 401 advanced asset reliability management: leaders accountable for 1 day / 15 max. public orReliability o key performance indicators asset reliability, program in-houseLeadership o visible reliability features sponsors o brown field/greenfield modelling practices o reliability input to new projectsREL 402 managing optimisation studies for team leaders of RCM or 1 day / 15 max. in-houseManaging maintenance, plant availability, LCC: reliability improvement computerReliability o facilitating projects teams and licensedProjects o data collection software o model quality review essential o Pareto analysis o roles and responsibilities o presenting project overviews o project completion reports50x specialist courses on specific equipment: trained members of RCM 1 day / 15 max. in-houseSpecialist o conveyors teams or industryCourses o mobile plant networks o electrical gear o instrumentation o crushing and grinding circuitsWorkshop designed for experienced reliability experienced reliability 4 days / 15 max.Expert Reliability practitioners who want to expand their practitioners (plus CMRP exam on knowledge base further, or extend their 5th day) skills in facilitating and conducting reliability studies 17
  • 17. “ POWERFUL SOFTWARE TO EqUIP yOU WITH THE RIgHT dECISION MAkINg TOOLS. “18
  • 18. SOFTWAREARMS Reliability sells, supports and implements theIsograph Suite of Reliability Software which empowersbusinesses to optimise the reliability, availability,maintainability, safety and risk in industries such as rail,nuclear, automotive, aerospace, mining, manufacturing,utilities, power generation, oil and gas, and defence.All software licences are available as network or stand alone installations to allowmaximum flexibility. Technical data sheets are available for each product on request.The software suite comprises the following products:> Availability Workbench Reliability Centred Maintenance, Availability Simulation, Life Cycle Costing, > Hazop+ Weibull Analysis. Hazard and Operability Analysis for Operators, Engineers and Management> Reliability Workbench Prediction, FMECA Studies, Reliability Block > NAP Diagrams, Fault Trees, Event Trees and Reliability and Availability Analysis for Markov Analysis Communications Networks> FaultTree+ > FRACAS+ Event Trees, Markov and Fault Tree Analysis Software FRACAS Software for Collecting, Recording and Analysing Failures> LCCWare SOFTWARE Life Cycle Cost Analysis for Evaluating the Whole Life > AttackTree+ Cost of a System Attack Tree Analysis Software for Modeling Threats against System Security. 19
  • 19. AVAILABILITY WORKBENCH Availability Workbench is a powerful, integrated software package that combines RCM with Availability Simulation, LifeCycle Costing, Data Analysis and integrates with corporate ERP systems, databases and CMMS software through an analytics portal. ARMS Reliability have worked in conjunction with Isograph, the software developers, to keep these products at the forefront of essential reliability decision making tools . ARMS Reliability have implemented Availability Workbench on many major projects in the resource sector, power generation and capital intensive industries since 1997. Availability Workbench performs all the Reliability Analysis neccessary to meet everyday needs, as well as perform RAMS on each phase of a large project.20
  • 20. Availability Workbench provides a fullyintegrated environment for:> Reliability Centred Maintenance: > Availability Simulation: Developing and maintaining a Reliability Performing full system availability and Centred Maintenance (RCM) program to capacity predictions utilising Reliability optimise your reliability and maintenance Block Diagrams (RBD) that take into account strategy; supports RCM standards such as complex dependencies on spares and other SAE JA1011, MSG-3 and MIL-STD-2173(AS). resources.> Weibull Analysis: > Life Cycle Cost Analysis: Analysing historical failure data from the Performing a Life Cycle Cost Analysis to CMMS to model the failure characteristics calculate the expected costs of your system of equipment. during its lifetime and model repair versus replace decisions.> Enterprise Reliability Portal: Integrating the reliability decision making tools with the CMMS to enable easy data transfer. It boasts a powerful analytics portal to the CMMS enabling graphic analysis of plant performance to initiate decision making. 21
  • 21. WHAT AVAILABILITY WORKBENCH EQUIPS YOU TO DO Asset Hierarchy Develop an asset hierarchy that drills down into systems and subsystems to maintainable items. Use for RCM studies or load to CMMS. Criticality Assign a criticality rank for each maintainable item. Define criticality thresholds to automatically assign criticality based on simulated results. Automatically assign criticality based on Work Order history. Can be used to check/validate initial rankings. FMEA Generate and print a list of Functions, Failures, Failure Modes and Effects for each maintainable item hierarchy. FMECA Rank failure modes by criticality in order of cost, safety, operational impacts. View a Pareto chart of predicted effects and dominant failure modes. Failure data Analysis Analyse sets of failure data and fit to curve of best fit. Where no data exists, assign representative parameters or use a wizard to define appropriate parameters. Update parameters as they become available from work order system. Optimise Maintenance Determine optimal maintenance task and frequency that gives lowest total cost or risk. group Tasks Group individual tasks to form a job or job plan. Optimise groups to check for the optimal grouped interval.22
  • 22. Simulate Scenarios Simulate alternative strategy scenarios comparing run to fail, existing plan versus optimised plan. Can also evaluate alternative design, level of redundancy and repair versus replace options.Produce Plan Print the optimised plan identifying tasks, labor, spares, duration, frequency, maintenance effectiveness, and electronically load to CMMS through file import/export or directly to SAP/Maximo/Ellipse through the portal.Predict Resources Predict spares usage and labor requirements for both planned and unplanned maintenance. Planned maintenance includes all inspections, monitoring, refurbishments, shutdown plans, and capital replacements.Zero based budget Print budget requirements.Risk Profile Identify risk exposure and major contributors. List any risks that exceed threshold levels.Utilise Libraries Drag and drop from and to library.Repair or Replace Optimise when you should continue to repair the asset or invest in with a replacement.Assess Availability Convert FMECA to Reliability Block Diagram and arrange logic to reflect system design including redundancy. Can link FMECA to RBD so changes in one will update predictions in the other.Assess Life Cycle Costs Draw cost predictions into Life Cycle Cost module and simulate costs.Update Input latest Failure data and re-simulate to identify any changes to optimal strategies. 23
  • 23. RCMCOST MODULE RCMCost is a maintenance simulation module of Availability Workbench that allows maintenance tasks to be evaluated over a lifetime. Allowing for ageing over a lifetime, the package calculates the cost of failure modes comparing the benefit against alternative strategies. It’s an empowering tool for maintenance practitioners who need to optimise maintenance activities against the risks of failure, and to predict future costs and performance levels. This package brings maintenance decision making into the “information age”. RCMCost supports Reliability Centred Maintenance standards such as SAE JA1011, MSG-3 and MIL-STD-2173(AS) by providing a structured method for entering FMECA data and simulating the effects of different maintenance strategies on cost, safety, the environment and operational issues. The RCM decision making process is therefore substantially enhanced by the ability to quickly simulate the effects of preventive tasks, inspection tasks and condition monitoring taking into account ageing, hidden failures, maintenance crew costs, spares costs, availability and more. This extremely powerful package is valuable as a preliminary first pass or as a part of an ongoing continuous improvement program. It can be used to capture and preserve engineering knowledge and to provide a quantitative means of updating strategies from work order history. RCMCost uses the language of the business (that is, dollars and risk) to support maintenance decision making. RCM is a procedure for determining maintenance strategies taking into account the prime objectives of a maintenance program: > Minimise Costs > Meet Safety and Environmental Goals > Meet Operational Goals24
  • 24. The RCM process begins with a failure mode and effectsanalysis which identifies the critical plant failure modes in asystematic and structured manner. The process then requiresthe examination of each critical failure mode to determine theoptimal maintenance policy to reduce the severity ofeach failure.This decision may include combinations of:> Scheduled Preventive Maintenance Tasks (Lubrication or Replacement)> On-Condition Inspections> Inspections for Hidden Failure> Condition Monitoring Alarms> Re-DesignThe chosen maintenance strategy must take into account cost,safety, environmental and operational consequences. The effectsof redundancy, spares costs, maintenance crew costs, equipmentageing and repair times must be taken into account along withmany other parameters.Once optimal maintenance policies have been recorded the RCM process providesplant performance predictions and costs, expected spares requirements andmaintenance crew manning levels.The powerful reporting tool within Availability Workbench empowers the user tocreate many reports to represent the results of the RCM analysis. The RCM process can be used to develop a living strategy with the plant model being updated when new maintenance history is available or design changes take place. The ERP module of the Availability Workbench equips the user to seamlessly update the CMMS with the resultant RCM maintenance strategy and analyse maintenance history as it accumulates. 25
  • 25. AVSIM MODULE A sophisticated Monte Carlo simulation The AvSim module can help you optimise package for analysing plant availability asset availability and life cycle costs and reliability using Reliability Block by modelling: Diagrams (RBD). The AvSim+ Monte Carlo > Plant availability and throughput simulator engine is the result of 16 years > Planned and predictive maintenance of evolutionary development. The simulator policies from RCMCost enables AvSim+ to model complex redundancies, common failures, ageing and > Shutdown intervals component dependencies which > Spare part tracking and stock-out cannot be modelled using standard > Equipment switching delays analytical techniques. > Tank storage levels > Seasonal operations > Duty/Standby systems Apply the Reliability Block Diagrams to make the logical connections which describe your plant and equipment arrangements, and the program will automatically deduce the failure logic of the system. Once you have defined the logical structure of your project you can define comprehensive failure and maintenance models to represent the performance of components within your plant. These models could be simple failure and repair models or they could represent complex dependencies including ageing, spares requirements, labor availability, operational phases and standby arrangements.26
  • 26. Consequences are then assigned to any level of the logical diagramto indicate the effects of failures (financial, operational, safety andenvironmental). Labour, spares and failure data may be importedor directly entered into the program together with any operationalphase information and task group assignments.The AvSim module may be used to simulate the effects of differentspares holding levels on lifetime costs. The user sets site anddepot minimum and maximum values for all selected spares.When performing a spares optimisation run AvSim will try sparesholding values within the specified range only.The program performs simulation runs for each combination ofspare part holdings (between range values) for each selected sparepart. Once all the simulation runs have been completed AvSim willdisplay the optimum spares holdings from a cost viewpoint at siteand depot.The AvSim module may be used to determine whether it isworthwhile performing planned maintenance or inspections oncomponents, and if so, what the optimal shutdown or turnaroundinterval should be.If a component exhibits ageing characteristics then plannedmaintenance may be effective in reducing the probability of asystem outage and hence reduce outage costs. However, theplanned maintenance task may have labour, spares and othercosts associated with it. Planned maintenance costs must bebalanced against reduced outage costs.Similarly, performing inspections for hidden or potential failureswill often reduce costs due to unscheduled outages. The benefitsof reducing the costs of unscheduled maintenance need to beweighed against the additional costs of performing more frequentinspections. The AvSim module locates the optimum intervalfor planned maintenance and inspection tasks by varying themaintenance interval and repeatedly simulating the lifetime costs. 27
  • 27. ENTERPRISE RELIABILITY PORTAL The Enterprise Reliability Portal (ERP) links a company’s Upload Maintenance Plans Enterprise Asset Management or CMMS to the Availability Workbench software. This provides Maintenance and The Maintenance Plan module of the ERP enables Reliability Engineers with a real-time decision making tool, you to transform optimised maintanance strategies utilising maintenance history to optimise maintenance directly into your CMMS from the RCMCost module of strategies through the use of advanced and mature reliability Availability Workbench. simulation tools. It gives you the ability to: The ERP allows you to create a “living program” through > Highlight new maintenance strategies that are ready the alignment of data captured in the CMMS with to load to the CMMS Availability Workbench and provides a continuous reliability > Determine whether tasks in the CMMS have been improvement process over the asset life cycle. changed and are different to the ones in Availability Workbench > Record changes and reasons for change when they are made > Create detailed and customised work instruction documents in Word or PDF format > Display existing maintenance strategies in CMMS.28
  • 28. Analyse Plant PerformanceThe analytics module of the ERP enables a view into the maintenance history in theCMMS. This module uses a drill down graphical display to allow the user to assess plantperformance and analyse areas where improvements can be made to initiate decisionmaking in Availability Workbench.Maintenance history can be viewed for individual equipment or for equipment classesacross the facility. This data can be converted to Weibull sets to analyse for failurecharacteristics, reliability growth and the effectiveness of current maintenance strategy.Handle Master DataThe ERP can transfer the data from the RAMS models to setup and configure theCMMS system. In a new plant or procured piece of equipment, a RAMS study should beperformed to justify the amount of equipment, amount of redundancy, risk and optimalmaintenance strategy. The information used in these studies is transferred directly tothe CMMS for the operational phase of that plant or equipment to ensure data alignmentbetween strategy and work management.Data that is typically loaded from Availability Workbench includes equipment hierarchy,equipment criticality, equipment classes, failure codes, spare parts and billsof materials.Build RAMS ModelsWhere there is existing data in the CMMS, it can be used to build a RAMS model utilising the ERP to extract the necessary information to map tothe Availability Workbench tables and fields. This process minimises time spent in data entry, freeing up engineers to focus more on analysis.Maintenance history can be viewed for individual equipment or for equipment classes across the facility. This data can be converted toWeibull sets to analyse for failure characteristics, reliability growth and the effectiveness of the current maintenance strategy. 29
  • 29. THE LIFE CYCLE COST ANALYSIS MODULE Life Cycle Cost analysis is used to evaluate the through-life cost of new plant or equipment. The user builds a hierarchical Cost Breakdown Structure (CBS) through an unlimited number of indenture levels starting at the conception stage and continuing through research and development, design, operations and maintenance and ending with system disposal. The items may be further subdivided until the cost of each element can be defined as a mathematical equation. At a simple level this can be the number of man-hours multiplied by a cost rate. The elements of cost will then be added together to give the total cost for each item and a grand total for the system through its full life. The CBS can be directly linked to cost predictions produced by the RCMCost or AvSim modules. Other costs may be defined as time-dependent cost equations or simple numerical values. Global variables may be defined and utilised in the cost equations. High level costs are determined either by summating the cost values for child nodes in the CBS or by applying a user-defined cost equation. The syntax of cost equations is easy to understand and the construction of cost equations is assisted by an intelligent code recognition utility that automatically reveals global variable lists as the user types in an equation. Phase-dependent cost equations can also be defined. Phases are shared between the LCC and AvSim modules. The LCC module allows users to define life cycle costs other than those predicted by the RCMCost and AvSim modules. These costs may be integrated with predicted costs in the LCC cost breakdown structure to provide a time-dependent analysis of a system’s whole life cycle cost process.30
  • 30. WEIBULLMODULEThe Weibull Analysis module of Availability Workbench analyses historical failure and repairdata by assigning probability distributions which represent the failure or repair characteristicsof a given failure mode used during an RCMCost or AvSim system simulation.The Weibull Analysis Module analyses times-to-failure and time-to-repair data using thefollowing distributions:> Exponential Distribution > Lognormal Distribution> 1-Parameter Weibull Distribution > Normal Distribution> 2-Parameter Weibull Distribution > Weibayes> 3-Parameter Weibull Distribution > Phased Bi-Weibull> Bi-Weibull > Phased Tri-Weibull> Tri-WeibullThe Weibull module automatically fits the selected distribution to the data provided and displays the resultsgraphically in the form of cumulative probability plots, unconditional probability density plots and conditionalprobability density plots. The plots may be viewed on the screen or printed to a report. 31
  • 31. NORTH AMERICA 3921 Steck Avenue Suite A120, Austin TX 78759 Ph: 512 795 5291 Fax: 512 795 5228 AUSTRALIA 6-8 Sinclair St Ocean Grove, VIC 3226 Ph: +61 3 5255 5357 Fax: +61 3 5255 5778Email: info@globalreliability.com www.globalreliability.com

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