arms reliability corporate brochure
TRANSCRIPT
At ARMS Reliability we value learning as a lifelong
process. Learning is dynamic with different
needs determining the best pathway to growth.
Our education pathways include skill-based
training, workshops, pilot studies, project
support, advanced skill training, mentoring,
auditing and user group networks. ARMS
Reliability students come from all levels:
experienced technicians, engineers,
managers, project managers and subject
matter experts. Our teachers are
experts too, who facilitate the learning
process through a range of flexible
delivery styles.
Equipped with powerful software
tools and the capacity to make
data-based decisions, our clients
can optimise the contribution of
assets to business performance. They can
make proactive decisions and achieve asset
management goals.
The ARMS reliability history is deeply rooted
in mining, manufacturing, power and utilities.
These industries have recognised that reliability,
availability, maintainability and safety are cost-
critical at all stages of a project lifecycle. They
see the value of building reliability into design
as early as possible and of installing continuous
improvement processes into existing operations.
Empowered, educated and equipped … they are
ready to meet the special challenges of their
individual business environments.
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.
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People
The passion and drive of our people to be
experts and apply their knowledge to the field
of Reliability is reflected in the enthusiastic
support we engender in our clients.
Partners
ARMS Reliability’s business relationship with
Isograph stretches back to 1997. During that
time we have regularly contributed to the
development of the Availability Workbench
suite. Isograph recognises ARMS Reliability
as experts in training and implementation of
the RCM and System Availability simulation
modules.
We have also maintained our relationship with
Apollo Associates since 1997 for the delivery
of Apollo Root Cause Analysis. Teaching
Apollo regularly is a true privilege that is
mirrored by students’ realisation that they can
analyse and solve problems of any complexity
with a simple four-step method.
Clients
Many of ARMS Reliability’s clients are long
term. Our most powerful marketing tool is
client referral, making satisfied customers
critical to our future.
We manage client relationships mindfully,
providing excellent service, efficiently, with
integrity, and listening to feedback so we can
continue to improve.
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ARMS RELIABILITY LEADERSHIP TEAM
The ARMS Reliability team are experienced practitioners
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-
tive behaviours, recognising that technical solutions
alone do not drive this transition. This premise has
remained unchanged since we commenced
operation in 1995.
Our goal is to perform on as wide a field as possi-
ble whilst maintaining our reputation for service
excellence.
PEOPLE, PARTNERS ANd CLIENTS
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Our Leadership
Michael Drew - Managing Director
Jason Apps - Technical Director
Darren Gloster - VP North America
Our Team
Erick Alingcastre Peter Horsburgh
Mark Arbuthnot Jack Jager
Jason Ballentine Andrew Blunden
Craig Brydges Ned Callahan
Brian Connors Allan Fox
Brian Heinsius Leigh Jarman
Julien Maffre Thomas Reddell
Rex Tomlins Stuart Tupper
Les Gibson Peter Kyselica
Greg Morphet Bob DiFrancesco
Dennis French Paul Daugalis
Customer Service Team John McIntosh Kelly Hickman
Tony Nye Paula-Jo Mitchell
Melanie Watkins
ARMS RELIABILITY LEADERSHIP TEAM
Software
The Isograph range is one of the most extensive available. One reason
it continues to be an industry leader is the simplicity of use it affords,
enabling the user to carry out otherwise complex analysis.
The joy for the ARMS Reliability Team in the teaching and implementation
of the Isograph suite is that using the RAMS software is intuitive, and leads
to powerful decisions based on sound logic. While Reliability concepts
may seem complicated and challenging, the Isograph tools equip the user
to embrace the concepts with confidence and to use them to arrive at
decisions without getting bogged down in mathematical complexity.
Training
ARMS Reliability has been delivering Reliability Training since 1995.
We prefer delivering experiential training because we know it provides
the most enduring learning. It is also most enjoyed by participants and
therefore more engaging. Our well-defined course materials cover a wide
cross-section of subject matter in the field of Reliability. We take particular
pride in teaching reliability concepts across a broad range of roles,
including managers, engineers, technicians and subject matter experts.
Services
Because we are expert practitioners, we can train effectively and continue
to provide direction for software development. We love to undertake and
complete projects and to see our clients achieving brilliant outcomes for
their enterprises.
What we offer
ARMS Reliability is a services,
training and software organisation
specialising in reliability analysis
and cause analysis for both new and
existing projects.
Our areas of expertise include:
> Reliability Centred Maintenance:
introductory and advanced
training, software, facilitation,
project completion.
> System Availability Modeling:
introductory and advanced
training, software,
project completion.
> Integrating Reliability with SAP,
Maximo, Ellipse: implementation,
configuration, training.
> Root Cause Analysis: training,
software, facilitation, incident
investigation.
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THE ARMS
RELIABILITY DIFFERENCE
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.
Our ability to model real world asset performance
and identify optimal maintenance and logistics
arrangements has been employed by utilities, rail and
power generators to improve asset management and
demonstrate improvements to owners, regulators and
internal stakeholders. Our people love the challenge
of turning around plant that is not performing due to
regular failures, low availability levels, or high costs of
maintenance. For us it’s a challenge, for our clients it
often means millions of dollars impact to their bottom
line. Increasingly, we are being asked to perform
RAMS studies at the preliminary design stage of major
projects. This allows us to build lifecycle models that
support proactive reliability, and ensure that asset
management systems are set up appropriately with
plans, task instructions, reporting codes and good
functional hierarchies.
It also enables meaningful performance measures to
be defined to enable targets and thresholds to be set,
alerting asset performance managers of deviations
before the asset falls into reactive maintenance mode.
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.
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THE ARMS
RELIABILITY DIFFERENCE Our Clients
Our clients come in all shapes and sizes and from a diverse range of industries and disciplines.
BHP Iron Ore Asset Reliability 2009-2010
BHP Potash
Blair Athol Coal
BMA Coal
BHP Illawarra Coal
Collohausi
Rasgas
Qatar Petroleum
Dalrymple Bay Coal Terminal
Peabody Energy
Anglo Gold
BHP Olympic Dam Expansion
Alcoa
Nyrstar
Sydney Water
SA Water
Watercare
Brisbane Water
Metro Water District Of
Southern California
Snowy Hydro
Portland General Electric
Avista
Vline
Qld Rail
EDI Rail
Key DifferentiatorsWhat differentiates ARMS Reliability from other Reliability service providers?
> People who are experienced, qualified, passionate and highly expert in Reliability methods.
> Isograph software: The most powerful RAMS software tools on the market.
> Integration of RCM with Asset Management Systems: SAP, Maximo, Ellipse.
> Efficient work methods proven over multiple clients and industries.
> Knowledge availability through extensive libraries of failure data, and maintenance templates.
> Proven training excellence.
> Success in small and large project completion.
> Success built on long term customer relationships.
What our clients say about us
“ Have engaged ARMS in our business globally with huge Business Improvement successes through delivering reliability, productivity and safety “
“ In terms of Asset Reliability processes and business improvement, as a business we would not hesitate in engaging ARMS as a partner “
“ The ARMS team is professional and has delivered results across all of our sites where engaged. With past results and the way ARMS conduct their business engaging our people, I would have no hesitation recommending ARMS to others “
“ 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
very high standard“7
“EMPOWERINg CLIENTS TO MAkE bETTER ASSET dECISIONS. “
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SER
VIC
ES
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ARMS Reliability provides expert services in the following
areas, encompassing all phases of asset life cycle for both
new and existing plants.
We focus on empowering our clients with the knowledge and expertise to respond to critical
questions about their plant performance across a full range of related disciplines.
SERVICES
Root Cause Analysis Facilitation> How do I find the best solution to prevent an
incident recurring?
> How do I reduce systemic causes impacting defects?
Incident InvestigationHow do I investigate a major incident?
RBD Simulation Modelling> Will my design deliver production objectives?
> Where are the critical bottlenecks which impact production capacity?
> Will my maintenance plans support the Plant Availability Target?
> What level of spares is cost effective to hold?
RCM Analysis> How do I develop maintenance plans for new
equipment or existing equipment?
> What Spares will I need?
> What labor resources do I need?
> Maintenance plan Evaluation
> Am I performing sufficient maintenance?
Maintenance Plan Optimisation> How can I reduce maintenance costs?
> How can I improve reliability?
> How can I improve availability?
> Capital Requirement Forecasting
> What capital do I need to budget over the
next 10 years?
Life Cycle Cost CalculationsWhat is the total life cycle cost of this project in
today’s dollars?
ARMS Reliability boasts a track
record of success in partnering
clients to achieve their design,
maintenance and performance
objectives. Our portfolio is cross-
platform and cross-industry,
including sizable and complex
projects such as:
> Major expansion of iron ore handling facility
> Major expansion of coal handling port facility
> Construction of greenfield alumina refinery
> Capital planning development for water and power utilities
> Assessment of maintenance plan for major hazardous facility chemical plant.
> Optimisation of maintenance plan of mining shovels and trucks
> Construction of mega-project to mine copper and uranium
> Evaluation of availability of large communications systems for land-based and marine warning systems
> Optimisation of maintenance plan of power generation
> Identification of “bad actors” of production facility and facilitate solutions.
> Development of zero-based budget for dairy industry
> Development of libraries for templating
a large utility.
Sydney Water – RCM and Rbd ModelingSydney Water is currently undertaking an
enterprise-wide drive to create a sound, consistent
and rational system on which it can confidently
base its business decisions. As a critical part of
this initiative, Sydney Water has engaged ARMS
Reliability to assist in building a reliability/
maintenance system that enables logical, auditable
and justifiable business decisions related to
asset performance.
This will be accomplished by creating RCM and
RBD models of its critical Sewer Treatment Plants,
Sewer and Water Pump Stations.
The RCM modelling exercise will deliver the
following features:
> capacity to identify, quantify and prioritise the
risks associated with equipment failures
> standard sets of meaningful maintenance
tasks that can be consistently applied across
relevant assets
The RBD modeling exercise will provide
capacity to:
> forecast availability system performance
> quantify plant risks, such as environmental
licence breaches.
Sydney Water – RCM and RBD Modeling
Fonterra Cooperative Group, New Zealand’s largest
company (by turnover), handles over a third of all
international dairy trade.
In September 2009, it commissioned the world’s biggest
milk dryer, capable of producing hundreds of tons of
milk powder per day.
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.
We also developed a reliability block diagram (RBD),
providing criticality analysis of capacity and availability
during the design phase.
The combination of the RCM-based maintenance
strategies and the RBD provided a quantitative analysis
platform from which capital and operational planning
decisions continue to be made
Fonterra Edendale - Maintenance Strategy and Critical Item Review
CASE STUDY: 1
CASE STUDY: 2
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EMPOWER EDUCATE EQUIP
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CASE STUDY: 3How Portland General Electric Used RCM to change their maintenance culture
Portland General Electric (PGE) serves over 800,000
customers within a 4,000-square mile service area, including
52 Oregon cities.
In 2006, PGE undertook a program to shift its maintenance
culture and to create a culture of proactivity.
Using facilitated RCM studies and training, ARMS Reliability
engaged with key stakeholders from PGE including a small
group of employees who undertook a 3 day intensive training
workshop.
The workshop centred on the RCM method of maintenance
task optimisation. The participants learned about the use of
failure data analysis and forecasting that reduce the costs
to their business. This was the first step in promoting a
proactive maintenance culture.
The results of a series of brief RCM studies at different PGE
generating sites were presented to the plant managers and
while impressive per se, they particularly enabled promotion
of the benefits of a proactive maintenance culture.
The argument that “RCM will not work here” or “proactive
maintenance is not for us” can no longer be sustained.
Since the initial studies, PGE has conducted others on a
boiler feedwater system, a circulating cooling water system,
a hydro generating power train, a heat recovery steam
generator and an ammonia system. Each was selected to
assist in the development of an optimised asset strategy
and to promote the benefits of RCM in achieving proactive
maintenance.
The culture change is an ongoing process but with the solid
commitment of all stakeholders, it is achieving its goal.
“ INTERACTIvE, HANdS ON, PRACTICAL TRAININg TO EdUCATE RELIAbILITy TEAMS. “
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TRA
ININ
G
For over 10 years industry has trusted ARMS Reliability to
help 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
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.
“ INTERACTIvE, HANdS ON, PRACTICAL TRAININg TO EdUCATE RELIAbILITy TEAMS. “
TRAINING
We offer training courses through either public or in-house delivery in the following subjects:
> Reliability Centred Maintenance
> Root Cause Analysis
> RAMS Analysis
> Plant Modelling
> Incident Investigation
> Implementing your RCM or RCA program
> System Availability Analysis
> FaultTree Analysis
> Reliability Methods
> Hazop Studies
> CMRP Exams
> Life Cycle Costing
> Reliability Excellence
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Design Engineers … who are looking to
use reliability analysis tools to improve the
reliability of design.
Asset Managers … who are looking to set
up their work management system in a way
that provides for continuous performance
improvement over the life of an asset
or plant.
Reliability Managers … who are looking to
improve the performance of their assets
whilst ensuring efficient use of resources.
Maintenance Planners … who need to
improve maintenance plans and resource
arrangements.
Risk Managers … who need to optimise
activities against the risk of failure and
catastrophic incidents.
Maintenance Practitioners … who are
looking to introduce an effective continuous
improvement strategy and involve the
workforce in improved decision
making methods.
Safety Managers … who need to investigate
incidents, reduce the risk of injury and
improve workplace safety.
General Managers, CEOs and Executives …
who want to understand how to maximise
business performance, increase output,
and improve organisational profits and
shareholder value.
Who should attend ARMS Reliability training?
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PROBLEM SOLVINGCourse Title Features and details Who Should Attend Duration Delivery mode
and Class Maximum
RCA 101e
Apollo eRCA
RCA 102
Apollo RCA Participant Course
RCA 201
Apollo RCA Practitioner Course
RCA 301
Apollo RCA Super User Course
RCA 401
Apollo RCA Managers Course
RCA 501
Failure Reporting
II 101
Incident Investigation
fundamentals of Apollo problem solving
computer-based training course, with registrants receiving 12 months online access to course materials
provides the knowledge and skills necessary to effectively utilise RCA and participate in problem analysis
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)
beneficial for anyone whose job includes problem solving
all participants receive copy of Realitycharting software
for facilitators with 6-12 months experience; aimed at improving skills in applying the method and ensuring success
for managers and supervisors not involved in the details of incident investigation, but having the need to direct associated activities
course can also be used as an overview for anyone interested in effective problem solving
tracking corrective actions and analysing failure data
basic incident investigation management
those seeking refresher training or located in remote areas
operators, maintainers, safety representatives
engineers, planners, supervisors and lead personnel
trained facilitators
department managers, superintendents.
those responsible for effective failure elimination
anyone required to manage an incident
2 hours
1 day / 25 max.
2 day / 25 max.
1 day / 15 max.
0.5 Day / 15 max.
1 day
2 days
online
public or in-house
public or in-house
(laptop an advantage)
in-house
in-house
in-house
public or in-house
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RELIABILITY TRAININGCourse Title Features and details Who Should Attend Duration and Delivery mode Class Maximum
failure rates, FMEA, FMECA, RBD, RCM, FaultTrees, LCC, failure reporting
workshop with exercises illustrating how to move a system from Reactive behavior to Proactive behavior using Reliability Methods.
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 are introduced to maintenance decision making using RCMCost.
participants receive booklet with typical reports out of RCMCost, including a maintenance plan and work instructions.
maintenance optimisation using RCM and life cycle simulation.
skill-building course on how to use RCMCost: o Weibull data analysis. o risk/cost benefits analysis. o maintenance task optimisation o plan development.
advanced features that allow more accurate emulation of reality: o hidden failures o redundancy factors o operating time factor 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
system analysis using Reliability Block Diagrams: o parallel and series dependencies o redundancy o importance ranking, o spares inventory holding o “what if” scenario analysis
Plant Capacity Determination: o process flow analysis o determining capacity o identifying bottlenecks o aligning shutdowns o “what if” scenario analysis o criticality analysis of complex systems
life cycle costs calculation: o cost tree development including sustaining
and acquisition costs o time value of money o rate of return and alternative scenario
comparison
1 day / 25 max.
2 days / 15 max.
2 days
3 days / 12 max.
2 days / 15 max.
2 days / 15 max.
1 day / 15 max.
1 day / 15 max.
public or in-house
public or in-house
public
computer and demo’ software essential
in-house
computer and licensed software essential
in-house
computer and licensed software essential
in-house
computer and licensed software essential
in-house
computer and licensed software essential
in-house
computer and licensed software essential
REL 101Reliability Roadmap
REL 102
Managing Reliability Improvement
RCM 101Managing RCM using RCMCost
RCM 201Maintenance Optimisation
RCM 301ADV Software Features and Manipulation
RBD 301Plant Availability Simulation
RBD 401Advanced Plant Availability Simulation
LCC 401
Life Cycle Cost Calculations
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engineers who require an overview of reliability methods
anyone seeking a more effective way to make and integrate maintenance decisions
anyone interested in learning how RCM simulation software can assist them
RCM team members involved in a maintenance improvement study
requires completion of RCM 201 and experience as an RCM team member
team members, process engineers, maintenance engineers
process engineers, maintenance engineers
project, plant and maintenance engineers, involved in asset selection and repair or replacement decisions
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Course Title Features and details Who Should Attend Duration Delivery mode and Class Maximum
quantitative risk analysis using fault trees and event trees: o initiator events o enabling events o importance analysis o event tree o scenario analysis
HASOP studies: o key words o setting criteria o risk matrix o hasard ranking
advanced asset reliability management: o key performance indicators o visible reliability features o brown field/greenfield modelling
practices o reliability input to new projects
managing optimisation studies for maintenance, plant availability, LCC: o facilitating projects o data collection o model quality review o Pareto analysis o roles and responsibilities o presenting project overviews o project completion reports
specialist courses on specific equipment: o conveyors o mobile plant o electrical gear o instrumentation o crushing and grinding circuits
designed for experienced reliability practitioners who want to expand their knowledge base further, or extend their skills in facilitating and conducting reliability studies
safety engineers, risk managers, instrumentation or control engineers designing level of protection.
team members involved in hazard assessment
leaders accountable for asset reliability, program sponsors
team leaders of RCM or reliability improvement teams
trained members of RCM teams
experienced reliability practitioners
2 days / 15 max.
1 day / 15 max.
1 day / 15 max.
1 day / 15 max.
1 day / 15 max.
4 days / 15 max. (plus CMRP exam on 5th day)
public and in-house
computer and demo’ software essential
In-house
computer and licensed software essential
public or in-house
in-house
computer and licensed software essential
in-house or industry networks
FTA 201Fault Tree Training
HAS 201Hazops
REL 401Reliability Leadership
REL 402 Managing Reliability Projects
50xSpecialist Courses
WorkshopExpert Reliability
“ POWERFUL SOFTWARE TO EqUIP yOU WITH THE RIgHT dECISION MAkINg TOOLS. “
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SOFT
WA
RE
ARMS Reliability sells, supports and implements the
Isograph Suite of Reliability Software which empowers
businesses 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 allow
maximum flexibility. Technical data sheets are available for each product on request.
The software suite comprises the following products:
SOFTWARE
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> Availability Workbench
Reliability Centred Maintenance,
Availability Simulation, Life Cycle Costing,
Weibull Analysis.
> Reliability Workbench
Prediction, FMECA Studies, Reliability Block
Diagrams, Fault Trees, Event Trees and
Markov Analysis
> FaultTree+
Event Trees, Markov and Fault Tree Analysis Software
> LCCWare
Life Cycle Cost Analysis for Evaluating the Whole Life
Cost of a System
> Hazop+
Hazard and Operability Analysis for
Operators, Engineers and Management
> NAP
Reliability and Availability Analysis for
Communications Networks
> FRACAS+
FRACAS Software for Collecting, Recording
and Analysing Failures
> AttackTree+
Attack Tree Analysis Software for Modeling
Threats against System Security.
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.
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AVAILABILITY WORKBENCH
> Reliability Centred Maintenance:
Developing and maintaining a Reliability
Centred Maintenance (RCM) program to
optimise your reliability and maintenance
strategy; supports RCM standards such as
SAE JA1011, MSG-3 and MIL-STD-2173(AS).
> Weibull Analysis:
Analysing historical failure data from the
CMMS to model the failure characteristics
of equipment.
> 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.
> Availability Simulation:
Performing full system availability and
capacity predictions utilising Reliability
Block Diagrams (RBD) that take into account
complex dependencies on spares and other
resources.
> Life Cycle Cost Analysis:
Performing a Life Cycle Cost Analysis to
calculate the expected costs of your system
during its lifetime and model repair versus
replace decisions.
Availability Workbench provides a fully
integrated environment for:
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WHAT AVAILABILITY WORKBENCH EQUIPS YOU TO DOAsset Hierarchy
Criticality
FMEA
FMECA
Failure data Analysis
Optimise Maintenance
group Tasks
Develop an asset hierarchy that drills down into systems and subsystems
to maintainable items. Use for RCM studies or load to CMMS.
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.
Generate and print a list of Functions, Failures, Failure Modes and
Effects for each maintainable item hierarchy.
Rank failure modes by criticality in order of cost, safety, operational
impacts. View a Pareto chart of predicted effects and dominant
failure modes.
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.
Determine optimal maintenance task and frequency that gives lowest
total cost or risk.
Group individual tasks to form a job or job plan. Optimise groups to
check for the optimal grouped interval.
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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.
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 spares usage and labor requirements for both planned
and unplanned maintenance. Planned maintenance includes all
inspections, monitoring, refurbishments, shutdown plans, and
capital replacements.
Print budget requirements.
Identify risk exposure and major contributors. List any risks that exceed
threshold levels.
Drag and drop from and to library.
Optimise when you should continue to repair the asset or invest
in with a replacement.
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.
Draw cost predictions into Life Cycle Cost module and simulate costs.
Input latest Failure data and re-simulate to identify any changes to
optimal strategies.
Simulate Scenarios
Produce Plan
Predict Resources
Zero based budget
Risk Profile
Utilise Libraries
Repair or Replace
Assess Availability
Assess Life Cycle Costs
Update
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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 Goals
RCMCOST MODULE
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The RCM process begins with a failure mode and effects analysis which identifies the critical plant failure modes in a systematic and structured manner. The process then requires the examination of each critical failure mode to determine the optimal maintenance policy to reduce the severity of each 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-Design
The chosen maintenance strategy must take into account cost, safety, environmental and operational consequences. The effects of redundancy, spares costs, maintenance crew costs, equipment ageing and repair times must be taken into account along with many other parameters.
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.
Once optimal maintenance policies have been recorded the RCM process provides plant performance predictions and costs, expected spares requirements and maintenance crew manning levels.
The powerful reporting tool within Availability Workbench empowers the user to create many reports to represent the results of the RCM analysis.
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AVSIM MODULEA sophisticated Monte Carlo simulation
package for analysing plant availability
and reliability using Reliability Block
Diagrams (RBD). The AvSim+ Monte Carlo
simulator engine is the result of 16 years
of evolutionary development. The simulator
enables AvSim+ to model complex
redundancies, common failures, ageing and
component dependencies which
cannot be modelled using standard
analytical techniques.
The AvSim module can help you optimise
asset availability and life cycle costs
by modelling:
> Plant availability and throughput
> Planned and predictive maintenance
policies from RCMCost
> Shutdown intervals
> Spare part tracking and stock-out
> Equipment switching delays
> 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.
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Consequences are then assigned to any level of the logical diagram
to indicate the effects of failures (financial, operational, safety and
environmental). Labour, spares and failure data may be imported
or directly entered into the program together with any operational
phase information and task group assignments.
The AvSim module may be used to simulate the effects of different
spares holding levels on lifetime costs. The user sets site and
depot minimum and maximum values for all selected spares.
When performing a spares optimisation run AvSim will try spares
holding values within the specified range only.
The program performs simulation runs for each combination of
spare part holdings (between range values) for each selected spare
part. Once all the simulation runs have been completed AvSim will
display the optimum spares holdings from a cost viewpoint at site
and depot.
The AvSim module may be used to determine whether it is
worthwhile performing planned maintenance or inspections on
components, and if so, what the optimal shutdown or turnaround
interval should be.
If a component exhibits ageing characteristics then planned
maintenance may be effective in reducing the probability of a
system outage and hence reduce outage costs. However, the
planned maintenance task may have labour, spares and other
costs associated with it. Planned maintenance costs must be
balanced against reduced outage costs.
Similarly, performing inspections for hidden or potential failures
will often reduce costs due to unscheduled outages. The benefits
of reducing the costs of unscheduled maintenance need to be
weighed against the additional costs of performing more frequent
inspections. The AvSim module locates the optimum interval
for planned maintenance and inspection tasks by varying the
maintenance interval and repeatedly simulating the lifetime costs.
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The Enterprise Reliability Portal (ERP) links a company’s
Enterprise Asset Management or CMMS to the Availability
Workbench software. This provides Maintenance and
Reliability Engineers with a real-time decision making tool,
utilising maintenance history to optimise maintenance
strategies through the use of advanced and mature reliability
simulation tools.
The ERP allows you to create a “living program” through
the alignment of data captured in the CMMS with
Availability Workbench and provides a continuous reliability
improvement process over the asset life cycle.
Upload Maintenance Plans
The Maintenance Plan module of the ERP enables
you to transform optimised maintanance strategies
directly into your CMMS from the RCMCost module of
Availability Workbench.
It gives you the ability to:
> Highlight new maintenance strategies that are ready to load to the CMMS
> Determine whether tasks in the CMMS have been 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.
ENTERPRISE RELIABILITY PORTAL
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Analyse Plant Performance
The analytics module of the ERP enables a view into the maintenance history in the
CMMS. This module uses a drill down graphical display to allow the user to assess plant
performance and analyse areas where improvements can be made to initiate decision
making in Availability Workbench.
Maintenance history can be viewed for individual equipment or for equipment classes
across the facility. This data can be converted to Weibull sets to analyse for failure
characteristics, reliability growth and the effectiveness of current maintenance strategy.
Handle Master Data
The ERP can transfer the data from the RAMS models to setup and configure the
CMMS system. In a new plant or procured piece of equipment, a RAMS study should be
performed to justify the amount of equipment, amount of redundancy, risk and optimal
maintenance strategy. The information used in these studies is transferred directly to
the CMMS for the operational phase of that plant or equipment to ensure data alignment
between strategy and work management.
Data that is typically loaded from Availability Workbench includes equipment hierarchy,
equipment criticality, equipment classes, failure codes, spare parts and bills
of materials.
Build RAMS Models
Where 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 to
the 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 to
Weibull sets to analyse for failure characteristics, reliability growth and the effectiveness of the current maintenance strategy.
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.
THE LIFE CYCLE COST ANALYSIS MODULE
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WEIBULL MODULE
The Weibull Analysis module of Availability Workbench analyses historical failure and repair
data by assigning probability distributions which represent the failure or repair characteristics
of a given failure mode used during an RCMCost or AvSim system simulation.
> Exponential Distribution
> 1-Parameter Weibull Distribution
> 2-Parameter Weibull Distribution
> 3-Parameter Weibull Distribution
> Bi-Weibull
> Tri-Weibull
> Lognormal Distribution
> Normal Distribution
> Weibayes
> Phased Bi-Weibull
> Phased Tri-Weibull
The Weibull module automatically fits the selected distribution to the data provided and displays the results
graphically in the form of cumulative probability plots, unconditional probability density plots and conditional
probability density plots. The plots may be viewed on the screen or printed to a report.
The Weibull Analysis Module analyses times-to-failure and time-to-repair data using the
following distributions:
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