RCM Release 3.13

July 2020

w-IMS RCM is used to develop a Maintenance strategy for Equipment based on a Reliability Centred Maintenance assessment. The following release notes describe the new functionality and improvements in version 3.13.

Besides stabilizations, version 3.13 contains a redesigned Maintenance Libraries functionality, enhancements of the Systems, Tasks and Change and Deferral screen, etc.

Maintenance Libraries

Maintenance Libraries (RSLs) are collections of Maintenance strategies (sets of tasks) grouped around Failure modes typical for a certain LOCATION TYPE or EQUIPMENT GROUP. In this release, a major redesign of the functionality is done, from building up the GLOBAL RSL service and updates, various functionality enhancements, user interface redesign, etc.

1. User interface redesign

The Maintenance Library details page is split in two main sections, the RSL Details section, and the Failure Modes and Tasks section. The Details section contains the details of the RSL and as its edit /update does not affect the assets to which RSL is assigned to, this section is not part of the newly introduced RSL revisioning process.

The GLOBAL RSL libraries contains an info box of the usage of current RSL on sites throughout the network.

Equipment GROUPS are also defined on the Maintenance Library level so to make sure the correct maintenance tasks are assignable to Equipment even in the case when IMS is not interfaced with any CMMS system.

1.1 Number Field

 A Number field is added in the details section. It’s a free text field so that a user can type number code for a Maintenance Library by which the Maintenance Library can be identified.

1.2 Description Field

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A description field is added in the details section. It’s a free text field so that a user can type a small summary around what equipment the Maintenance Library should be applied to, various notes etc.

1.3 ‘No Scheduled Maintenance' Strategy

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For every Maintenance library a ‘No Scheduled Maintenance' Strategy can now be activated. This means that when that strategy will be applied to the assets, there will be an option to deliberately choose not to do any maintenance (no tasks) for that asset.

1.4 Failure Modes List Section

The Failure modes section is a section on the far-left column of the RSL details screen and is intended to add/remove Failure Modes from the library. In the initial, Draft version of the library Failure modes are added via the ‘+’ sign, which opens the dialog box for selecting the Failure modes compatible with the RSL Location types / Equipment Types.

The selected Failure mode is indicated by different color and all the failure mode buttons have a check box for selecting them and then to be able to delete them via the ‘-’ button.

1.5 Failure Modes Details Section

The selected Failure mode details are shown in the Failure mode Details section. Here the user can set:

• Applicable Equipment Types
• Failure Effects,
• Criticality Scenario,
• Criticality using Criticality Matrix,
• Strategy,
• add and set Maintenance Tasks,
• Estimated Time Between Consequences,
• set Equipment Care Strategy parameters & rules etc.

1.6 PF Interval and Safe Lifetime

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PF interval and Safe Lifetime are added in the Strategy section as parameters on the adequate strategies, so when they can be set here in the RSL template and then copied to the equivalent fields in the RCM analysis when applying the RSL to FLOC / Equipment.

2. Task Relevance Depending on Specs

Task Relevance Depending on Specs approach for assigning the Failure modes is introduced as an optimized set of tasks applicable from a certain Maintenance Library to an asset (FLOC or Equipment).

Applying the strategy to the assets is done by help of specifications set on the FLOC or Equipment: based on their values a certain task from the Maintenance Library will be applicable and some will not.

For setting the rules there is a Equipment Care Strategies Section where the user can:

• Chose a Spec on which a decision should be made (based on the Equipment Group which is covered by a Maintenance Library)
• Get a list of unique tasks for all the Failure modes of the library
• Set if a task is applicable for a certain combination of Spec / Spec value

On basis of those parameters Strategies are automatically created and a list of applicable strategies will be available to the user when applying the Library to the Equipment.

The names of the strategies are automatically generated but a naming functionality (for giving an ‘Alias’ to each strategy) is available.

3. Version control and approval

An approval functionality is introduced. Both LOCAL and GLOBAL RSLs will undergo an approval process thus improving the version control of the RSLs. For the approval process the generic concept for revisioning is used (Approval Event). Since there’s need to always have a RSL in IN_EFFECT state (to be assigned), for altering any parameter which has impact on the Maintenance Strategy (FM, Tasks etc.) a DRAFT version of the current APPROVED RSL should be created prior to its approval.

Revisions sequences are added to the RSL objects automatically, starting with 1 and proceeding with ordinal numbers, so there is a continuity in the RSL history.

Statuses of the RSL library can be as follows:

Upon approval, the version replaced by the actually approved version will still visible in the tool but will become deactivated (commonly marked with a grey line) and thus will not be available for further assigning to the assets.

This deactivated RSL library can still hold relations to assets to which were previously assigned, but the function for synchronizing to latest version will be available.

The Version data and controls are shown on the grey bar dividing the Details and the Failure Modes section:

• Status (DRAFT / IN_EFFECT)
• Revision
• Delete / Edit buttons
• Approval control button

Upon approving, the approver will be requested to enter the Reason for edit, thus making the reason for a change more transparent to the users.

3.1. Creating new and comparing revisions

A draft version of the Maintenance Library become available for assignment when final approved. If there is need to change the Failure Modes on the RSL, by using the Edit button a new version will be created, and the IN_EFFECT and the DRAFT version will be both shown in the same screen

While the IN_EFFECT revision is locked for editing, on new version the following changes can take place:

• A failure mode can be added
• A failure mode can be deleted
• A failure mode attribute can be changed

In order to facilitate the tracking of the changes to the approver, the equivalent indicators will be shown:

4. Import / Export for import

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The import and export for import procedures are introduced in the standard importer tool, using template.

The tool can be accessed via Settings / Data Transfer / Import Data or via the button on the Maintenance Library toolbar.

The standardized import Template is used, which can be found in the tool.

5. Applying the applicable Failure modes

5.1 Bulk Applying the RSLs using Bulk Actions

Now the Failure modes from Maintenance Libraries can be assigned in bulk using the Bulk Actions feature from the FLOC or Equipment grid.

Next to the previously existing System Failure Modes tab a RSL Failure Modes tab is added, to let the user chose from the Global or Local Maintenance Libraries for compatible Hierarchy Types / Equipment Groups.

Similar to the issue described in the chapter 1.5.3, as the FLOC / Equipment can be assigned only to one Maintenance Library at the same time, the list is locked on failure modes belonging to just one library as soon as the user selects first failure mode.

5.2 Applying the RSLs on the FLOC/Equipment details

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Applying the Failure modes from Maintenance Libraries is done using the same Bulk Actions functionality adapted to assigning just one FLOC/Equipment. By using the Bulk Actions, it is now possible to assign the FLOC/Equipment to the System and to its Functions / Functional Failures as well.

If the FLOC/Equipment is already assigned to a System, that value is preselected and cannot be changed through this functionality.

5.3 Filtering of the Failure modes for FLOCs (System details)

The functionality for applying the RSL failure modes to FLOCs is improved and a new logic is added to the way of presenting the right RSL library as a primary choice. While on the FLOC level all the failure modes defined for the LOCATION TYPE are applicable, the list on the grid is filtered using the following additional filters:

On the FIRST assignment:

• Using SAP Types on the FLOC, if there isn’t any then
• Using SAP Types on the belonging equipment, if there are any, if not then
• Using just the FLOC Location Type

On all other assignments:

• Locking the list only on RSL to which the firstly assigned FM belongs

Dashboards

1. RSL Dashboard

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The RSL Dashboard is a RSL site-specific dashboard with indicators of RSL versions and changes. It contains three sections of counts:

• Recent updates,
• Misalignment (due to RSL revisions)
• Usage.

2. RSL Global Analyses Dashboard

 The Global Analyses Dashboard provides an overview of the state of RCM analyses and bad actors combined with the usage of available global templates per site.

3. RSL Global Usage Dashboard

The Global Usage Dashboard provides an overview of all available Global RSL’s with counts for the sites that use them. This dashboard helps administrators maintaining RSL templates understand the impact if changes throughout the community.

4. Global MEC Dashboard

A Global MEC Dashboard is introduced with the following KPI’s:

• AMS/MEC % of equipment with risk-based assessment
• # of PEI LOPCs and incidents
• # of RCM analyzed FLOC/Equipment
• MEC Assessment Coverage
• RCM but not RBI
• non-PEI Equipment
• PEI Equipment
• RBI but not RCM

5. SAP Dashboard

SAP Dashboard is added to RCM module.

6. New Dashboard Feature

The creation of new dashboards is completely redesigned with the goal to make it easier and simpler, and to improve visualization of the data.

There is a new dashboard picker, a wizard which will walk you through the steps to create a dashboard, multiple visualization styles, preview of the elements being created, manual correction and adjustments of all elements, drill down function, filtering on selections, tracking trends with historic data, etc.

Change and Deferral Requests improvements

 Various improvements of the Change and Deferral functionality were introduced: tiered levels of approval, possibility to add attachments and comments without interrupting the approval process, added columns to the CHD grid etc.

1. Tiered Approval Levels

Tiered levels functionality now lets the site to organize the approval phase in a sequential way, using the Tier Level attribute for any approver added to the Change and Deferral request. The layers are named by common ordinal numbers and the field is mandatory (default value: First) so all users will be put in hierarchy order.

The same functionality is implemented in the Settings / AutoApproval section.

When an initiator starts the approval process the mail notification and the Approve/Reject buttons will be made available to the approvers on the lowest Tier Level. In the fashion of the current design, only when they all approve the request, the next tier level is initiated (notification, buttons). If any approver rejects the request, the process is immediately stopped, and all the involved users are notified. In this way, the process continues through all existing levels in that request, and finally gains the Approval status when the user in the highest tier (or more of them) give his approval.

1.1 Changes to the AutoApproval Selection lightbox

When defining approver in AutoApproval functionality, besides the Location, Type of Change and the Discipline, now the Tier Level is introduced as a mandatory field.

1.2 Changes to the Add Approvals lightbox

When adding approvers manually in the CHD request, the Tier Level should also be specified:

1.3 Changes to the Approval Stage grid

All the approvals and their Tier levels are shown in the Approval Stage section of the grid.

1.4 Adding attachments

With the above described functionality, the request to include for instance the “Subject matter expert” in the approval process will be fulfilled as he can be added as a user in the first tier, so the approval process will not have to be interrupted. When the Subject matter expert adds the requested documentation, he can approve his stage and the mail with the notification (including the info of the added attachments) will be sent to the approvers on the next level.

2. Change Request Implementation Date

Implementation date of the Change and Deferral request is added to the CHD grid to facilitate the user obtain their month end metrics.

3. Other enhancements

• A Change / Deferral request includes a mandatory Unit field. Only when users select a value for the unit, Location and Equipment fields become visible. They are marked with the light blue colour, indicating that those are recommended field (but not mandatory in exclusive way).

• The selected unit is now used as a prefilled value for the scope filter in the dialogue boxes for the selection of FLOC or Equipment. The user can still override this filter and select assets from any place in hierarchy
• The grid is now showing added info (e.g. Location Type etc.)

Tasks improvements

 Various improvements of the Tasks functionality were introduced.

1. Tasks Filters Added

The following filter options have been added to the Tasks screen:

• Equipment Group
• Equipment Type
• Failure mode
• MEI range

2. Labels

 Labels functionality is added to the Tasks screen.

3. Tasks Import / Export for Import

 Now it is possible to do the export for import and to change Tasks attributes using import. Since this import is basically a stripped version of the RCM analysis import, all the recalculation of the data which impacts the RCM analysis to which the tasks are hooked on are made.

The ECS tasks are omitted from updating through this import because they are linked directly to the ECS Strategies and have to be changed using the ECS revisioning mechanism.

4. Tasks – Task Source

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In the preparation work for tasks which are scraped from existing PM work instructions or from Corrective Maintenance work orders, a field showing the Task Source is added. The values are:

• Maintenance Work Instruction
• CM Work Order

5. Tasks – Mandatory Reason

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As part of the improvements to adhere to the MEC Standard and Manual, the tasks reason for being mandatory is now more descriptive.

The added reasons are:

• SCE
• Production Critical
• Non Critical
• Regulatory
• Other

This feature will allow the assets to be document why a task is mandatory based on the categories required from the MEC Standard and Manual.

If a user chose to enter a reason that is not on the Mandatory Reason list, he can choose option “Other” and then a free text box for entering a reason will be shown.

6. Tasks – Implementation System moved to Settings

 Now the list of Tasks implementation systems become a table in the Settings section of the application, thus enabling the Site admin to define new implementation systems.

It can be found in Setting - Maintenance – RCM Specific Data – Implementation System.

Equipment Care Strategies improvements

1. Distinguish Tasks in Strategies matrix by Task ID

The autonumbering function to distinguish tasks having the same name in the Strategies/Tasks matrix has been removed and instead of it, the Task ID value is used.

For this purpose, the Task ID value is made mandatory and unique.

2. Secondary Tasks option added

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A task can be now defined as “Secondary” which means it is a Task that is driven by a TA interval set on the Plant or Unit level. Secondary tasks do not stick to their own Maximum interval, but their interval is set at half time of the interval calculated for his primary task.

3. Redesigned ECS Strategies grid

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The way the strategies are presented and composed is now more intuitive.

ECS Tasks are presented in vertical way taking much less screen width, and a TaskID and Task description is added to the grid.

Various usability enhancements

1. System uniqueness extended

 Uniqueness defined previously on Systems by Unit and Name is extended. Now the uniqueness is defined with:

• Unit
• System number
• Name

2. Automatic System number generated

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An automated generation of the System numbers is introduced: the user does not need to look at the first available number and then enter it manually to be associated with the newly generated System, but the tool automatically picks the next available one and assign it to the System.

System numbers are generated using the keywords SYSTEM and an 8-digit counter, thus allowing to have 99999999 different systems per site.

System number is created upon saving and it is shown in the System details and cannot be changed.

To preserve old data, the existing system numbers were added to the end of the value contained in the Description field.

3. Equipment group field added to FLOC grid

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Equipment group field was added to FLOC grid.

4. Label names show the color of their label in the filter

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In all main grids (FLOC, Equipment, Systems, Analysis, Tasks, etc.) where labels and their filters are available, their labels are now shown with the label color used as a background to let the user find the desired label in the filter in a quicker and easier way.

5. Perform RCM indicator added to FLOCs / Equipment

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On the FLOC and Equipment, a checkbox Perform RCM is added, suitable for marking the assets on which the RCM analysis should be performed. When selected on FLOC level, the underlying Equipment inherits its value.

6. Multiple Tag search filter on Systems

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A Tag Range filer is added to the Add Tags to System dialog box.

It can be accessed via the +/- Flocs/Equipment button on System details

7. Recommended Tasks field optimization

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Visible area for Description / Notes / Materials / spare parts field has been increased to accommodate more text and make text entries more visible and readable.

8. Status ‘completed’ added to the Study tab in Systems

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A new value ‘Completed’ is added to the Status drop-down for Studies in System details. It can be accessed via the + button in the Study Section.

9. Show only assigned tags checkbox added to Functional Failures

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‘Show only assigned tags’ checkbox is added to Add Tags to Functional Failure dialog box thus making the removal of the already added tags from Functional failures easier.

10. Improvements in SAP interface

Strategy based plans will now also have a cycle representing the shortest cycle in the operation package.

Resolved issues