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Exploitable results
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
result
The database is a fundamental device of the developed sw tool since it allows the recording of rough historical data on the components constituting the system which are fundamental for the processing of the reliability data that are the starting basis for the application of the sw tool itself.
Obviously, in consideration of the main features of the method, the development of a database component oriented was mandatory. It allows the recording of the following data on each component of the system: identification data, data on its environment, engineering and operating characteristics, maintenance data, failure data and refined data progressively processed on the component.
By those data, an identification of the component is allowed not only in terms of its initials and position in the installation but also in terms of its project and operating characteristics so that their identification and an intervention on them is possible if it results necessary in order to improve the performances of the component. Once the single physical component is so identified, the database allows the storing of "historical" data on each one of them in terms of carried-out maintenance operations and occurred failures. These historical data, suitably selected, will be used to process reliability data on each component type.
Other records of the database also allow an automatic storing of the refined data progressively obtained by the application of the different modules constituting the software tool and constituting the automatic input of the following ones.
The database has been developed in a generalized way. To this aim, records allowing the storing of all the above information were provided. But they are supplied void to the end-user so that he may adapt them to his real necessities.
The software of the database is ready to be used by each end-user applier. Obviously, it may be applied in each industrial field. It may also be used independently of the other methods constituting the main sw tool. Its degree of innovation consists of the detail of information which may be recorded in it, of its generalized characteristics so that it may be adapted to each type of necessities and of its interactive connection with the other methods constituting the main software tool.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
If the tests of point 3 may be applied, a further method allows the automatic selection of the components on which maintenance must be applied and its preliminary definition. To this aim, the method performs an automatic analysis of the time trend of the failure rate of each interested component type and of its importance: the only components having an increasing failure rate and important in the system operation will be selected as the ones on which maintenance must be applied. The method also allows a preliminary definition of the maintenance strategies to be applied on the components so selected on the basis of the operations to be performed in order to eliminate the systematic failure causes generating the increasing of the failure rate. In order to define the maintenance type, the experience information recorded in the database will be also used; concerning the maintenance execution interval the time on which the increasing failure rate crosses the constant failure rate will be chosen.
The method may be only used in connection with the above reliability data processing methods. It is a really innovative method and it may be applied in each type of industrial system. Its application is really important in the case of systems constituted by a high number of components.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
The definition of the maintenance strategies is independently performed by the method of the above point 4 on each single component. They must be necessarily improved at system level to find the best maintenance configuration of the equipment corresponding to the minimum of the management costs in the respect of prefixed constraints on its reliability, safety, availability, etc.
It follows that a further method was set-up allowing a realistic simulation of the analysed system on the basis of its operating flow diagram and of the characteristics of its components (failure rates, repair times, failure and repair costs, etc.) specified in the input of the method itself. Since failure rates varying in the time had to be considered, the use of Montecarlo techniques was mandatory. On the basis of the application of these techniques and of the data specified in its input, the code allows a realistic simulation of the considered system and a consequent realistic evaluation of its availability and management costs. Iterative calculations based on the variation of the maintenance strategies specified in the input and on the comparison of the quantities printed in the output allow the singling-out of the best system management configuration.
In particular, the following performances may be obtained by the application of the code: main components and component piece parts life simulation on the basis of their failure rate specified in the input, possibility of specifying different failure rates for each failure cause of the same component (or piece part), taking into consideration of different components typologies (continually operating, intermittent, stand-by), detection and undetection of the failure, presence of incipient failures which may be detected by suitable controlling instruments or inspections, different types of repair (remote repair included), all types of preventive maintenance and its effects on the component (partial or total renewal), inspections to detect hidden failures, inspections to detect incipient failures and providing the replacement of the component before its failure and propagation if they are not detected, tests on stand-by components.
A high limit of the method is the impossibility of using it independently of the other modules constituting the main sw tool. In any case, as explained above, since it allows the simulation of each type of maintenance, it may be considered an innovative method in the field. It was suitably tested in the project. Obviously, as the other methods constituting the main sw tool, it may be applied in each industrial field.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
These methods, interactively connected with the database, allow the data entry and enquiry. For these reasons, they may be only used in direct connection with the database.
Concerning the data entry, the developed computer program allows so a direct manual entry by the end-user as the automatic transfer from other databases.
The program for the data selection allows, by the use of suitable menus, so the research of a single rough datum as the automatic selection of datasets to be used as input of the computer programs for the reliability data processing.
In connection with the database, they constitute a very important device which allows the direct data recording (so directly by the operators who perform the maintenance activities in the workshops as transferring them from an existing database) and the selection of the rough data to be used for the reliability data processing (to this aim "homogeneous" datasets may be selected on a well defined component type, etc.)
.The methods are ready to be marketed and, in connection with the database, they may be applied in each industrial field.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
Aim of the activity was an adaptation of all the developed software to the manufacturing industry and the demonstration that it may be profitably applied to improve the existing maintenance planning and consequently to obtain high savings in the maintenance management costs and an increase of the system reliability and availability. To demonstrate the achievement of this last objective, quantities suitably defined had to be quantified on the basis of the exploitation and their values measured before and after the application of the method had to be compared.
At the end, the following results were obtained (between parentheses the tasks in which they were achieved):
- definition of the exploitation quantities to be used for the demonstration of the achievement of the prefixed objectives (task 8a);
- adaptation of the database to a particular manufacturing industry defining (by codes or numerical values) the void records constituting it (task 8b);
- transfer into the new database of all the available historical data (i. e.: information on the occurred failures and their repair and on the carried-out maintenance operations) previously recorded in an existing CMMS database (task 8c);
- processing, on the basis the recorded historical data, of refined reliability data on each component type constituting the chosen production line (task 8e,f);- improvement of the maintenance planning at system level by the application of the system reliability analysis code. Quantification, by it, of parameters defined at the beginning of the project and characterizing the maintenance management of the system. Comparisons of the quantities so calculated with the correspondent values obtained from the exploitation (task 8e,f and 8g).
Such results are useful for future applications of the developed sw tool in the manufacturing industry in terms of adaptation of the method and mainlines to be followed.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
result
The database is a fundamental device of the developed sw tool since it allows the recording of rough historical data on the components constituting the system which are fundamental for the processing of the reliability data that are the starting basis for the application of the sw tool itself.
Obviously, in consideration of the main features of the method, the development of a database component oriented was mandatory. It allows the recording of the following data on each component of the system: identification data, data on its environment, engineering and operating characteristics, maintenance data, failure data and refined data progressively processed on the component.
By those data, an identification of the component is allowed not only in terms of its initials and position in the installation but also in terms of its project and operating characteristics so that their identification and an intervention on them is possible if it results necessary in order to improve the performances of the component. Once the single physical component is so identified, the database allows the storing of "historical" data on each one of them in terms of carried-out maintenance operations and occurred failures. These historical data, suitably selected, will be used to process reliability data on each component type.
Other records of the database also allow an automatic storing of the refined data progressively obtained by the application of the different modules constituting the software tool and constituting the automatic input of the following ones.
The database has been developed in a generalized way. To this aim, records allowing the storing of all the above information were provided. But they are supplied void to the end-user so that he may adapt them to his real necessities.
The software of the database is ready to be used by each end-user applier. Obviously, it may be applied in each industrial field. It may also be used independently of the other methods constituting the main sw tool. Its degree of innovation consists of the detail of information which may be recorded in it, of its generalized characteristics so that it may be adapted to each type of necessities and of its interactive connection with the other methods constituting the main software tool.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
Aim of the activity was an adaptation of all the developed software to a transport system constituted by buses and the demonstration that it may be profitably applied to improve the existing maintenance planning and consequently to obtain high savings in the maintenance management costs and an increase of the system reliability and availability. To demonstrate the achievement of this last objective, quantities suitably defined had to be quantified on the basis of the exploitation and their values measured before and after the application of the method had to be compared.
At the end, the following results were obtained (between parentheses the tasks in which they were achieved):
- definition of the exploitation quantities to be used for the demonstration of the achievement of the prefixed objectives (task 7a);
- adaptation of the database to the bus transport field defining (by codes or numerical values) the void records constituting it (task 7b);
- transfer into the new database of part of the available historical data (information on the occurred failures and their repair and on the carried-out maintenance operations) previously recorded in an existing CMMS database. Adaptation, to this aim, of the data transfer program (task 7c);
- processing, on the basis the recorded historical data, of refined reliability data on each component type constituting the chosen subsystem (task 7e,f);
- selection of the components on which maintenance must be carried-out and its preliminary definition on the basis of an automatic analysis of the time trend of their failure rate and of their importance (task 7e,f);
- improvement of the maintenance planning at system level by the application of the system reliability analysis code. Quantification, by it, of the parameters defined at the beginning of the project and characterising the maintenance management of the system. Comparisons of the quantities so calculated with the correspondent values obtained from the exploitation (task 7e,f and 7g).
Such results are useful for future applications of the developed sw tool in the transport field in terms of adaptation of the method and mainlines to be followed.
Original research objectives. Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
Aim of the activity was an adaptation of all the developed software to the field of cogeneration power production plants and the demonstration that it may be profitably applied to improve the existing maintenance planning and consequently to obtain high savings in the maintenance management costs and an increase of the system reliability and availability. To demonstrate the achievement of this last objective, quantities suitably defined had to be quantified on the basis of the exploitation and their values measured before and after the application of the method had to be compared.
At the end, the following results were obtained (between parentheses the tasks in which they were achieved):
- definition of the exploitation quantities to be used for the demonstration of the achievement of the prefixed objectives (task 9a);
- adaptation of the database to a power cogeneration plant defining (by codes or numerical values) the void records constituting it (task 9b);
- transfer into the new database of all the available historical data (i. e.: information on the occurred failures and their repair and on the carried-out maintenance operations) previously collected (task 9c);
- processing, on the basis the recorded historical data, of refined reliability data on each component type constituting the chosen subsystems (task 9e,f);
- improvement of the maintenance planning at system level by the application of the system reliability analysis code. Quantification, by it, of parameters defined at the beginning of the project and characterizing the maintenance management of the system. Comparisons of the quantities so calculated with the correspondent values obtained from the exploitation (task 9e,f and 9g).
Such results are useful for future applications of the developed sw tool in the field of the power production plants in terms of adaptation of the method and mainlines to be followed.
Original research objectives.
Development, setting-up and validation of an innovative software tool, based on reliability and cost criteria, which, by its industrial application to the improvement of the maintenance planning of equipments, integrates and completes the traditional and existing CMMS (Computer Maintenance Management Systems) allowing to reduce the economic losses and to improve their availability.
The methods developed allow the processing of each type of reliability data (failure rate, average repair time, average cost of each maintenance or repair operation, average time between maintenances of the same type, etc.). Different methods were developed in function of the consistency of the dataset to be processed and of the type of result to be obtained.
Concerning the consistency, methods based so on the classic as on the bayesian statistics were developed. Concerning the type of data to be processed, since the methodology is mainly based on the analysis of the time trend of the failure rate, particular care was dedicated to the methods developed to obtain it.
First of all, tests to single-out the time trend (bathtub or part of it) of the "total" (i. e., independently of the failure causes) failure rate better approximating the available data-field, have been developed. Two tests were set-up to this aim. The second one is also connected with sw methods which allow (always considering all the assembly of the occurred failures) the direct evaluation of the distributions better representing each approximated trend (as said above, the complete bathtub or part of it) and the "change points" (i. e. the transition points from one trend to the other). It is so possible to calculate a total failure of a component, very important solution for the cases in which the failure causes are not available, common occurrence in many industrial installations. But its application is also important in the cases in which the failure causes are specified: the total failure rate so obtained allows a first selection of the components on which maintenance must be effectively applied. This method may only be applied if at least 50 data are available If the failure causes were specified, other methods, denominated "classical methods", allow the evaluation of different failure rates (represented by only one statistics distribution) for each failure cause. Such methods may be applied also in the case that few data (fewer than 50) are available to evaluate the total failure rate (in this case represented by only one distribution). They also allow the processing of other reliability data such as the average repair time, the average time between maintenances, etc.
At last, the bayesian methods allow the processing of all the above reliability parameters also in the case that very few rough data are available.
All the above methods may be used in connection with the database (i. e., the input is constituted by datasets obtained enquiring the database) as independently (i. e., the input is constituted by datasets obtained from the literature or otherwise). The methods are ready to be marketed and they may be applied in each industrial field. An important degree of innovation is given by the tests and the connected methods for the direct computation of the total failure rate, complete bathtub included.
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