Reliability HotWire

Issue 124, June 2011

Hot Topics

Asset Performance Management Using Orion eAPI

Asset performance management provides the means to effectively manage costs and maximize availability and throughput, thereby allowing an organization to reach its business objectives. For asset performance management to be effective, companies need to apply a system that will assist in the appropriate analysis and interpretation of available data, and generate an incisive set of key performance indicators (KPIs) in order to support strategic decisions.

This article will provide an overview of how Orion eAPI can be used for effective asset performance management and focus on the analysis modules that are available within the system.

Orion eAPI Overview

Orion eAPI is a centralized, web-based, enterprise system focused on asset performance management. The system automatically collects many types of data from different databases within an organization then performs filtering, basic statistical analysis, reliability analysis and other data management operations. This provides a comprehensive array of search, reporting and analysis capabilities that will enable an organization to accurately assess equipment performance and effectively manage valuable assets.

Because effective asset performance management requires the cooperation of multiple individuals and groups throughout the organization, Orion's web-based user interface can be accessed by a variety of individuals with different responsibilities and in different locations. System administrators can assign access levels, which determine the privileges and types of information that different users can access within the system.

Orion eAPI can interface with many different databases and CMMS/EAM systems (including SAP®, Maximo®, Oracle®, Access®, SQL Server®, etc.) — reading the information and storing it in a centralized, keyword-searchable database that supports the reliability analyses and other metrics that you need for effective asset management. The imported data may include:

  • System hierarchy (functional structure) and details about the equipment
  • Equipment work orders
  • Production loss data (e.g., from production event logs)
  • Predictive maintenance data
  • Scheduled preventive maintenance tasks

Figure 1 shows an overview of the Orion eAPI system.

Orion eAPI System Overview
Figure 1: System overview

Features Overview

The Orion eAPI system was developed to streamline the asset management process for managing operation and maintenance costs. Orion eAPI includes the following modules:

  • Portals (Individual and Group)
  • Key Performance Indicators (KPIs), such as MTBF, MTTR, Production Losses, Availability, Bad Actors, etc.
  • Analysis Modules
  • ReliaSoft Files Integration
  • Improvements/Actions Management
  • Target Management
  • Reports
  • Search

This article will focus on the different analysis modules that are available within Orion eAPI.

Analysis Modules in Orion eAPI

The analysis modules include several features that allow users to perform, manage and view various analyses. The analyses included in Orion will allow users to perform accurate asset management using the best methodologies and analyses available in the reliability engineering field.

The following analysis modules are included:

  • Life data analysis (LDA, a.k.a. Weibull analysis)
  • Reliability tracking/reliability growth (i.e., Crow-AMSAA analysis)
  • Spare parts forecasting
  • Root cause analysis (RCA)
  • Analysis management/integration with additional analysis tools
    • Risk analysis
    • FMEA
    • RCM
    • RBD and Fault Tree

Life Data Analysis (LDA)

One of the most powerful modules in the Orion system is the LDA module. This module was developed to streamline life data analysis using imported data from the customer’s database. This module uses the same calculation/plotting engines from ReliaSoft’s Weibull++ software to perform the calculations and all reliability analyses.

The highlights of this module include:

  • Automatically populates the failure and repair data from the information imported from the database.
  • Allows for analysis based on work orders or production losses (inherent or operational analysis).
  • Can automatically choose and fit the most appropriate distributions for the failure and repair data, based on ReliaSoft’s unique Distribution Wizard.
  • Enables treatment of the original data in order to clean up inconsistencies, while maintaining the original data intact. 
  • Allows automated analysis of the treated data.
  • Provides multiple analysis options, such as different distributions, different parameter estimation methods, confidence bounds methods, etc.
  • Automatically creates plots for failure and repair models.
  • Automatically creates reports on the analysis.
  • Provides automated analysis interpretation of results, including recommended actions to assist the analyst in the decision-making process.

The following figures are examples of some of the available outputs in the LDA module.

Distribution Information and Results
Figure 2: Distribution information and results

Reliability and Maintainability Tables
Figure 3: Reliability and maintainability tables

Reliability and Maintainability Plots
Figure 4: Reliability and maintainability plots

Reliability Tracking/Reliability Growth

Similar to the LDA module, the Reliability Tracking/Reliability Growth module allows the analysis of imported data based on work orders or production losses.  However, in this module only the failure or event data is considered (i.e., no repair data).  The reliability tracking is performed using the Crow-AMSAA model.

Cumulative Number of Failures Plot
Figure 5: Reliability tracking using the Crow-AMSAA model

Spare Parts Forecasting

This module was developed to define the optimum quantity of spare parts, taking into account the following inputs:

  • Lifetime distribution
  • Repair distribution
  • Failure costs
  • Spare parts costs
  • Lead time
  • Repair probability factor
  • Number of units operating in the field

Spare Parts Forecast - Table of Costs
Figure 6: Table of costs for different numbers of spare parts

Total Cost vs. Number of Spare Parts
Figure 7: Plot of total cost vs. number of spare parts

Root Cause Analysis (RCA)

The Root Cause Analysis module was developed to allow users to apply the RCA methodology to any level of the hierarchy. The system provides users with a web-based tool where they can build their root cause analysis using a cause-effect tree. 

It is important to highlight the following features of this module:

  • The user can associate an RCA to any part of the functional structure.
  • The user can publish this RCA to groups. Once an RCA is published in one or more groups, all users who belong to these groups will be able to view the RCA in their respective Group Portal.
  • The user can attach multiple external files to an RCA.

Figure 8 gives an example of an RCA in Orion eAPI.

Root Cause Tree
Figure 8: Root cause analysis in Orion

Reliability Centered Maintenance and FMEA

Using this module, users can view FMEA and/or RCM analyses that have been performed with ReliaSoft's Xfmea and/or RCM++ software and have been associated to various parts of the function structure. This feature allows users to have access to previously performed FMEA and RCM analyses, even if they did not participate in the process, so that they can learn more about their assets and contribute to the process, thus improving the quality of the analysis.

FMEA/RCM Analysis
Figure 9: FMEA/RCM analysis

Key Performance Indicators

Orion eAPI offers a variety of key performance indicators (KPIs), including:

  • MTBF
  • MTTF
  • MTTR
  • Availability
  • Number of Failures
  • Predictive Maintenance Costs
  • Preventive Maintenance Costs
  • Corrective Maintenance Costs
  • Maintenance Labor Costs
  • Spare Parts Costs

This module includes the KPI Dashboard, which can display various indicators selected by the user, as shown in Figure 10.

KPI Dashboard
Figure 10: KPI dashboard