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.
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.
Figure 2: Distribution information and results
Figure 3: Reliability and maintainability
tables
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.
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
Figure 6: Table of costs for different numbers 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.
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.
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.
Figure 10: KPI dashboard |
