PM Tasks and Intervals

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Recommends PM (preventive maintenance) tasks and intervals for over 100 common industrial infrastructure component types, such as motors, pumps, breakers, valves, and compressors.  Tasks are keyed to component functional importance, duty cycle, and service conditions.  Provides task scope, objectives, sensitivity analysis of reliability to the task interval, the most and least important tasks, and the technical basis for the activity.  This data is a key resource for planning and optimizing a plant PM program.

Failure Mechanisms

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Provides detailed and comprehensive lists of known failure mechanisms, hardware affected, driving influences and the time scale of all equipment deterioration processes, including the effects of service stressors, and the effectiveness of the recommended PM tasks in each case.  This information (for all component types) drives the link between PM tasks and equipment reliability and is a key resource for failure cause evaluations conducted by all plants seeking to improve reliability.

As-Found Reportable Conditions

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Generates, prioritizes, and edits lists of reportable conditions specific to each PM task and component type.  This data is a key resource for feedback from the shop floor, accelerating learning about what is not working in the PM program, enabling improvements to be made without waiting for expensive in-service failures, and avoiding waste of resources on unnecessary PM tasks.

Condition-Based Reliability

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Calculates the failure rate of all component types for explicit operating conditions consisting of PM tasks, task intervals, duty cycle, and service stressors.  Generates these predictions for the recommended PM program, for user-defined equipment PM programs, and for the run-to-failure condition.  Ranks and displays the most serious challenges to the PM program, the most likely causes of failure, and failure mechanisms that have good and poor protection by the PM tasks.  Shows explicitly the strengths and weaknesses of the PM program.  Enables what-if scenarios to be explored starting from the recommended or user-defined PM program.

Reliability/Availability Trade-Off

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Shows if a proposed change to the PM program is balanced from the perspective of reliability gained/lost in relation to equipment downtime increased/decreased.  Optimizing a PM program for critical equipment involves knowing when a point of diminishing returns is being reached as PM activities are added but improved equipment availability becomes harder to achieve.

Equipment Functional Importance

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Provides the ability to determine and document the functional importance of components in the plant so that PM resources can be applied where most needed.

Economic Risk

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Calculates the economic risk caused by failure of any critical component in the plant, given
      1) the consequence information that the user supplied for the determination of the functional importance of the equipment, and
      2) the equipment failure rate and average repair time that are calculated within the database.
      This risk is the sum of the production or other losses and the direct costs of maintenance.  Production losses include those due to in-service failures and those due to maintenance having to take the equipment out of service in order to perform the scheduled PM tasks.  Equipment outage hours for performing each PM task are suggested by the on-line database, but they are editable by the user - as is the degree to which planning and scheduling can avoid a production loss.
      Direct costs include costs of preventive and corrective maintenance, and take into account the benefits of predictive activities that enable some on-condition repairs to be performed more efficiently than if they progressed to be in-service failures.
      These results do far more than just inform users of the relevant costs.  They enable the user to base PM task and frequency selections on reliability versus availability cost trade-offs.  They enable users to make allowances for the impact on the production manager's budget, the maintenance manager's budget, on the bottom line for the company, and with regard to stability of the production process.
      Bottom line numbers include the return-on-investment (ROI) for the marginal PM dollar, so users can justify increased spending on the PM program to push production to the maximum, or make sensible cut-backs when the business cycle or competitive pressures move against the company.
      Users can move effortlessly from a barely adequate PM program to a blue-chip program, and quickly use the on-line PM Tips to focus in on world class but cost-optimized PM activities that suit the company's objectives.  Pro-M provides annual risks in dollars and compares user-defined PM program risk with the recommended risk, quantitatively and graphically.

PM Task Deferral Risk

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Estimates the economic and reliability risk of one-time deferral of important PM tasks conditional on knowing when important PM tasks were last performed.  This is a key resource for planning effective use of major plant outages and minimizing the risks of plant operation until the deferred PM tasks can be implemented.

Plant PM Builder

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Offers users a workstation to optimize their plant PM program component by component, automatically drawing in recommended PM information from the database, and making available all the database reliability analysis tools and risk estimation capabilities.  Enables user to make and edit PM library groups and other functional groups (user-defined) of components to streamline analysis of similar components, enables progress on the project to be tracked, and the results to be exported to the plant CMMS.  Provides for analysis of skid and train combinations of components.  The Plant PM Builder is optimized for the user who has enormous numbers of components to address as fast as possible, as well as the user who wants to carefully refine the PM program for a production critical asset and concurrently optimize the ROI and the avoided cost.

Reliability Performance Criteria

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Provides the capability to set and evaluate reliability performance criteria for components and systems and analyzes the criteria from a statistical perspective, accounting for the effectiveness of the criteria and the false alarm rate.  Enables what-if scenarios to be explored.