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OMCS International OMCS International Reliability Assurance Reliability Assurance Software SuiteSoftware Suite

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IntroductionsIntroductions

Who is OMCS International…Who is OMCS International…

Operations and Maintenance Consulting Services Pty Ltd.

In business for fourteen years. Developed the PMO2000™ Reliability Assurance

methodology. Currently has sites in Australia / NZ, USA / Canada

throughout Asia and Europe, Russia, Saudi Arabia / Middle East, South Africa and South America: 65% of our clients are SAP, Over 20 sites with BHP Billiton.

Key features of the software..Key features of the software..

It is not a straight jacket.. Can perform the following: RCM to SAE JA 1011. PM Optimisation. RCM Blitz. Risk Based Inspection. Quantitative Risk Assessment.

Fully certified integration with SAP® .

Developed as an enterprise package. One database – multiple sites.

Key features of the software..contKey features of the software..cont

Start to finish analysis with living program: Not a single bullet approach.

Designed for use in live workshop environment. Inbuilt approval and document control. Built with implementation in mind:

We analyse to implement, Creates documents that allow pictures and drawings

and endless layout types for work instructions. Open database and onboard report generators to

allow users to generate their own reports and KPI’s

Key features of the software..contKey features of the software..cont

Massive capability to assign permissions down to user and function level: All user actions can be traced.

Build around a framework of library analysis: Create masters and then clones, Update master allows users to update clones, First software to have a SPAWN system.

Key features of the software..contKey features of the software..cont

Build nested or independent task lists. Links with SAP® Catalogues. Can check out sections of the analysis for remote

workshop applications off the server then check back in.

User defined colour scheme to assist users identify the process.

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Software OverviewSoftware Overview

The cornerstones of reliability assurance…The cornerstones of reliability assurance…

SAP

DowntimeData

Management

PMO/RCM

Reliability Investigation Management

(FRACAS)

Even though the system is modular, all features can Even though the system is modular, all features can be called from a central screen.be called from a central screen.

All information can be viewed through one portal

The system ties in with the SAP business unit The system ties in with the SAP business unit and equipment structureand equipment structure

The independence of the software allows The independence of the software allows reliability to build equipment to deeper levelsreliability to build equipment to deeper levels

World’s best graphics with drill down to World’s best graphics with drill down to assist analysis and project managementassist analysis and project management

The process has six steps including The process has six steps including approval and implementation…approval and implementation…

Key features – Equipment Structure, Tasks and Key features – Equipment Structure, Tasks and Task Lists (Schedules)Task Lists (Schedules)

PMO2000™ Risk and Criticality ModulePMO2000™ Risk and Criticality Module

Risk Calculator FunctionsRisk Calculator Functions

• View inherent and residual risk Note that “Perceived Risk“ numbers areallocated by

the user based on the calculations. Typically the user would allocate risks between 1 and 10 with anything above 7 being unacceptable.

Assess inherent and residual risks as Assess inherent and residual risks as requiredrequired

Assess inherent and residual risks as Assess inherent and residual risks as requiredrequired

Note that there are an infinite array of categories (safety, production etc)

And independent scales that can be applied for relative consequences of each category

For Risk Based Inspections… Change the For Risk Based Inspections… Change the interval as the risks are updatedinterval as the risks are updated

Perform PM OptimisationPerform PM Optimisation

Evident

Perform Classical or Streamlined RCMPerform Classical or Streamlined RCM

Options for RCM Blitz fields...Options for RCM Blitz fields...

Uses SAP Failure CodesUses SAP Failure Codes

All features drive from a central screenAll features drive from a central screen

How to use EDA.... Red / Yellow / BlueHow to use EDA.... Red / Yellow / Blue

Review downtime

against strategy

PMO2000™ produces task lists in word or PMO2000™ produces task lists in word or adobe that document link in SAP..adobe that document link in SAP..

Add picturesor drawings to your tasks via PMO2000™Software

Users can do lots of things with Task Lists – Users can do lots of things with Task Lists – Pictures or tables can be added.Pictures or tables can be added.

Advanced permissions system suitable for Advanced permissions system suitable for enterprise level analysisenterprise level analysis

Store or link documents to element / object in the Store or link documents to element / object in the softwaresoftware

Powerful library analysis in many areas of the Powerful library analysis in many areas of the softwaresoftware

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The SAP interfaceThe SAP interface

https://www2.gotomeeting.com/register/328786227

The benefits of seamless integration with The benefits of seamless integration with SAPSAP One version of information consistent across the

business” Failure codes Equipment lists Maintenance schedules and tasks Reliability labour and cost accounting Comparison between costs and equipment

effectiveness Flexibility to customize specialist analysis methods

Preparing and sending schedules to SAPPreparing and sending schedules to SAP

SAP login details and master dataSAP login details and master data

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Reliability Reliability Investigation and Investigation and

ManagementManagement

Failure Reporting and Corrective Action System

(FRACAS)

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The process of The process of Investigation Investigation ManagementManagement

Investigation Management is a Investigation Management is a simple seven step process…simple seven step process…

1. Originate and Commit1. Originate and Commit

3. Analysis & Recommendations3. Analysis & Recommendations

6. Review Results6. Review Results

4. Approve4. Approve

5. Implement5. Implement

7. Archive7. Archive

2. Allocate Responsibilities2. Allocate Responsibilities

Key functions of Reliability Investigation Key functions of Reliability Investigation System (Rimsys)System (Rimsys) Information security. Simplicity of retrieval. Broadcasting capability giving endless opportunity

to: gather experience, knowledge and solutions, and distribute wisdom and new policy.

Quick detection of system bottlenecks by knowing who has what work to complete.

Simple means of tracking KPIs. Defines the process of investigation by leading

users through the software.

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Many sources of inputMany sources of input

Three Methods

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Post request to database with Web based FormPost request to database with Web based Form

Post request to database with MS Word.dot Post request to database with MS Word.dot template with send functiontemplate with send function

Post request directly into databasePost request directly into database

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Defining the Defining the Investigation ProcessInvestigation Process

Event

FMECA

RCA

Engineering Request

General Issues

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Define the Investigation Process as RCA, FMEA, Define the Investigation Process as RCA, FMEA, Engineering Request, GeneralEngineering Request, General

The process is defined and

displayed in the “process” column

Software will guide the user through the

process based on Process selection

Use and Root Cause Analysis method and Use and Root Cause Analysis method and store in databasestore in database

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Data AnalyticsData Analytics

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FeaturesFeatures

Takes data from From SCADA From PI Manual logs

Reconciles downtime with production rate

Enterprise Data Analytics…Enterprise Data Analytics…

Allows you to get rid of your spreadsheets and have one system world wide for all your plant performance data

Simple but comprehensive data captureSimple but comprehensive data capture

One database – design your own data needsOne database – design your own data needs

Pipeline Screen

Production Screen

Storage Screen

Fleet Screen

Once you have the data – you have the Once you have the data – you have the knowledge and capacity to manageknowledge and capacity to manage

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Combined Data Combined Data Analytics and Log Analytics and Log BookBook

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One combined system for log books and One combined system for log books and downtime recordingdowntime recording

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User defined ReportsUser defined Reports

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Build your own report and store them for use by Build your own report and store them for use by any userany user

Create your own hard copy reportsCreate your own hard copy reports

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SPAWNSPAWN

Systematic process of analysing maintenance requirements for like

assets, in different working environments, using imaging

technology networks.

An Overview of the SPAWN systemAn Overview of the SPAWN system

The right maintenance for every design and operating context / environment

This capability is so easy with SPAWN technology

Step 1 – Create Base Line AnalysisStep 1 – Create Base Line Analysis

The SPAWN system creates baseline machine and equipment structures that cover All design permutations for that equipment type, All operating environments, and Full RCM, FMEA or PMO for every permutation that

exists.

Step 2 – Create Design VariantsStep 2 – Create Design Variants

In this step, the user creates images of the baseline representing each design variant. Note that this also provides links to the complete

RCM, PMO or FMEA . This is done using a right click. The user then right clicks on the design variant

image components to delete the component links between the baseline and design variant.... Thereby creating a perfect image of the specific

equipment design.

Step 2 – Create Design VariantsStep 2 – Create Design Variants

Step 3 – Create Operating Context VariantsStep 3 – Create Operating Context Variants

In this step, the user creates images of the design variant representing each design and operating context variant.

Note that this also provides links to the complete RCM, PMO or FMEA .

This is done using a right click . The user then right clicks on the operating context

variant image tasks to delete the task links between the design variant and the operating context variant.... Thereby creating the correct maintenance strategy for

specific equipment design in the specific operating context

Step 3 – Create Operating Context VariantsStep 3 – Create Operating Context Variants

The key to SPAWN The key to SPAWN

Maintenance strategies are created can be developed in any image, however they are all attached to the baseline equipment structure.

The SPAWN software module has been created to manage this in a seamless fashion with the additional benefit of allowing SPAWN to be deployed more quickly and accurately than the previous cloning methods available in the PMO2000® software.

There is no other software in the market that contains SPAWN technology

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Analysis by system Analysis by system and functionand function

Release 2010

Analyse by systems and systems function and Analyse by systems and systems function and criticalitycriticality

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Bill of MaterialsBill of Materials

Fully integrated with SAP

Fully interfaced BOM SystemFully interfaced BOM System

Inventory Cash Release Inventory Cash Release Methodology by Phill SlaterMethodology by Phill Slater

Takes your stores holdingTakes your stores holding

Shows where your money is tied upShows where your money is tied up

Takes the user through a formal process to Takes the user through a formal process to address the issuesaddress the issues