Maintenance Optimization Modules

Overview

The maintenance-related modules of AllAssets are:

• Maintenance Strategies
  • Failure Modes and Effects and Analysis
  • Criticality Analysis
  • Reliability Centered Maintenance

• Maintenance Optimization
  • Each of these modules is inter-connected and can be used individually or in conjunction with the other modules.
  • For example, a user would be able to access and develop a maintenance strategy using the ‘Maintenance Strategy’ module or could use the ‘Maintenance Optimization’ module to optimize an existing strategy from the library of maintenance strategies.

Equally, the modules are able to be used and assigned to an asset register and hierarchy of equipment this can be derived from:

• User input assets and hierarchy
• Import from a CMMS/EAM export/download (see our integration capabilities here)

Maintenance Strategies

Within AllAssets you can create Maintenance Strategies. These libraries are organized following an ISO 14224:2016 ‘Petroleum, petrochemical and natural gas industries - Collection and exchange of reliability and maintenance data for equipment’ structure. Although this is an O&G standard, it provides an appropriate architecture for the taxonomy to be applied to a Maintenance Strategy library independent of the industry as shown below.

Keep in mind that although you cannot change the levels presented in the system, they are adaptable enough so that you can accommodate the classification to meet your needs.

Typically only levels 1 – 6 of the taxonomy will be ordinarily used for Maintenance Strategies; however, the structure of AllAssets permits for the creation of strategies at any of the 9 levels. The taxonomy coding from ISO 14224 can be applied to the relevant Maintenance Strategy and there is no limit to the number of Maintenance Strategies able to be created at any taxonomic level. Additionally, attributes are used to organize multiple strategies at a taxonomic level, for example:

• Speed
• Capacity
• Size / power
• Driver type

For example, you could have different Pump Strategies defined for the following different attributes:

Within Maintenance Strategies, the following elements are available:

• Boundary text and diagram
• Failure rates library - which follows an FMEA structure
• Performance Standards
• Planned Maintenance Activities

This module allows you to perform Failure Modes and Effects Analysis (FMEA), Failure Modes and Criticality Effects Analysis (FMECA) and Reliability-centered Maintenance (RCM).

The RCM module is intended to provide compliance with the following Standards and references:

• SAE JA1011, Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes
• IEC 60300-3-11, Edition 2.0 2009-06, International Standard Dependability management – Part 3-11:
• Application guide – Reliability centered maintenance
• MOD Defense Standard 00-045 Part 3, Guidance on the Application of Reliability Centered Maintenance
• MIL-STD-3034A, US Department of Defense Standard Practice Reliability Centered Maintenance (RCM) Process
• BS EN 60812:2006, Analysis techniques for system reliability – Procedure for failure mode and effects analysis (FMEA)
• Norsok Standard Z-008, Criticality analysis for maintenance purposes
• API RP 691, Risk-based Machinery Management
• RCM-II, Reliability-centered maintenance

Many of these standards describe a specific process, procedure or decision logic to be adopted in the execution of FMEA, FMECA or RCM. It is not the intent of AllAssets to reproduce faithfully all processes adopted in these standards but to provide a framework that will enable each of the standards to be implemented, recognizing that elements of the process will be managed externally to the software. In this approach, it is recognized that processes and decision logic external to AllAssets will be required.

Maintenance Optimization

The Optimization methodology implemented in AllAssets is the result of 10 years of research and market experience and implementation. This method has been used in many projects with customers where improving the interval of their Planned Maintenance based on their Maintenance Strategy was the main concern.
Maintenance can be optimized based on one or more of the following selectable options

The following describes in more detail what each method entitles:

Availability and Reliability: criteria are used to optimize Planned Maintenance based on:

• Target reliabilities (or availabilities), usually expressed as a %
• Failure Rate

Typically for a Planned Maintenance activity, the Planned Maintenance interval is derived to meet target reliability (or availability) for a given Failure Rate for an equipment item. The methodology for Availability and Reliability optimization is per the method developed for AllAssets.

Probability of Failure on Demand (PFD): is a measure used to specify the performance requirements of Safety Instrumented Systems (SISs). Safety Integrity Levels (SILs) are typically used to express the performance of Safety Instrumented Systems (SISs) and are defined in terms of SIL levels, ranging from 1 – 4. Each SIL level has a range of PFDs that describe the SIL levels as shown below.

Typical SISs are constructed of several components:

• Input devices, typical configurations are 1 out of 1 (1oo1), 1oo2 or 2oo3
• Logic solver, typical configurations 1oo1 and 1oo2
• Output devices, typical configurations are a single device to be activated, or several devices in series to be activated

The input devices, logic solver and output devices may have different Failure Rates, Planned Maintenance activities and Planned Maintenance intervals.

Commercial Impact: two types of commercial criteria are considered:

• Inspection (and Repair) of equipment during a Planned Maintenance activity
• Failure of equipment between Planned Maintenance activities

Both cases consider commercial impacts in terms of:

• Revenue Stream
• Labour
• Material
• Others

These criteria will not all be presented to the user, instead, the user should be able to add line items of commercial impacts for the Inspection (and repair).
If you want to learn how to use the maintenance optimization module, please go to the corresponding topic here.