ARMS Reliability is a service, training and software organisation providing a “one stop shop” for Reliability Engineering, RAMS and Maintenance Optimization for both new and existing projects. Our aim is to empower our clients with the knowledge and expertise to make asset management decisions,that optimize plant maintenance, reliability and availability at the lowest cost and risk.

2. THESE THREE kEy ELEMENTS dRIvE THE ARMS RELIAbILITy bUSINESS.
Empowering our clients to make better decisions underpins our training, our
services and our software. It provides our clients with the means to adapt new
methods and enhance their core competency. It goes beyond the training room
– empowerment is about learning and applying new methods, then measuring
outcomes and seeking opportunities for continuous improvement.
At ARMS Reliability we value learning as a lifelong assets to business performance. They can
process. Learning is dynamic with different make proactive decisions and achieve asset
needs determining the best pathway to growth. management goals.
Our education pathways include skill-based
training, workshops, pilot studies, project The ARMS reliability history is deeply rooted
support, advanced skill training, mentoring, in mining, manufacturing, power and utilities.
auditing and user group networks. ARMS These industries have recognised that reliability,
Reliability students come from all levels: availability, maintainability and safety are cost-
experienced technicians, engineers, critical at all stages of a project lifecycle. They
managers, project managers and subject see the value of building reliability into design
matter experts. Our teachers are as early as possible and of installing continuous
experts too, who facilitate the learning improvement processes into existing operations.
process through a range of flexible
Empowered, educated and equipped … they are
delivery styles.
ready to meet the special challenges of their
Equipped with powerful software individual business environments.
tools and the capacity to make
data-based decisions, our clients
can optimise the contribution of
2

3. People Clients
The passion and drive of our people to be Many of ARMS Reliability’s clients are long
experts and apply their knowledge to the field term. Our most powerful marketing tool is
of Reliability is reflected in the enthusiastic client referral, making satisfied customers
support we engender in our clients. critical to our future.
We manage client relationships mindfully,
Partners providing excellent service, efficiently, with
integrity, and listening to feedback so we can
ARMS Reliability’s business relationship with
continue to improve.
Isograph stretches back to 1997. During that
time we have regularly contributed to the
development of the Availability Workbench
suite. Isograph recognises ARMS Reliability
as experts in training and implementation of
the RCM and System Availability simulation
modules.
We have also maintained our relationship with
Apollo Associates since 1997 for the delivery
of Apollo Root Cause Analysis. Teaching
Apollo regularly is a true privilege that is
mirrored by students’ realisation that they can
analyse and solve problems of any complexity
with a simple four-step method.
3

4. ARMS RELIABILITY
Our Leadership PEOPLE, PARTNERS ANd CLIENTS
Michael Drew - Managing Director
Jason Apps - Technical Director
The ARMS Reliability team are experienced practitioners
Darren Gloster - VP North America and experts in reliability and root cause analysis.
The business was founded on a passionate desire to
empower other companies to move away from reac-
Our Team tive behaviours, recognising that technical solutions
Erick Alingcastre Peter Horsburgh alone do not drive this transition. This premise has
Mark Arbuthnot Jack Jager
Jason Ballentine Andrew Blunden
remained unchanged since we commenced
Craig Brydges Ned Callahan operation in 1995.
Brian Connors Allan Fox
Brian Heinsius Leigh Jarman
Julien Maffre Thomas Reddell
Our goal is to perform on as wide a field as possi-
Rex Tomlins Stuart Tupper ble whilst maintaining our reputation for service
Les Gibson Peter Kyselica
Greg Morphet Bob DiFrancesco excellence.
Dennis French Paul Daugalis
Customer Service Team
John McIntosh Kelly Hickman
Tony Nye Paula-Jo Mitchell
Melanie Watkins
4

5. LEADERSHIP TEAM
What we offer Software
ARMS Reliability is a services, The Isograph range is one of the most extensive available. One reason
training and software organisation it continues to be an industry leader is the simplicity of use it affords,
specialising in reliability analysis enabling the user to carry out otherwise complex analysis.
and cause analysis for both new and
The joy for the ARMS Reliability Team in the teaching and implementation
existing projects.
of the Isograph suite is that using the RAMS software is intuitive, and leads
to powerful decisions based on sound logic. While Reliability concepts
Our areas of expertise include: may seem complicated and challenging, the Isograph tools equip the user
to embrace the concepts with confidence and to use them to arrive at
> Reliability Centred Maintenance:
decisions without getting bogged down in mathematical complexity.
introductory and advanced
training, software, facilitation,
project completion. Training
ARMS Reliability has been delivering Reliability Training since 1995.
> System Availability Modeling:
We prefer delivering experiential training because we know it provides
introductory and advanced
the most enduring learning. It is also most enjoyed by participants and
training, software,
therefore more engaging. Our well-defined course materials cover a wide
project completion.
cross-section of subject matter in the field of Reliability. We take particular
> Integrating Reliability with SAP, pride in teaching reliability concepts across a broad range of roles,
Maximo, Ellipse: implementation, including managers, engineers, technicians and subject matter experts.
configuration, training.
> Root Cause Analysis: training, Services
software, facilitation, incident Because we are expert practitioners, we can train effectively and continue
investigation. to provide direction for software development. We love to undertake and
complete projects and to see our clients achieving brilliant outcomes for
their enterprises.
5

6. THE ARMS IFFER ENCE
IABIL ITY D
REL
ARMS Reliability provides a “one stop shop” for Reliability programs,
for both new and existing projects. We have proven success on RAMS studies for
significant new projects where our Reliability experts develop whole-of-project
models including design verification, maintenance plan optimisation, budget
forecast, risk evaluation, resource requirements, auto loading plans and matching
technical work plans to Asset Management Systems.
ARMS Reliability provides a “one stop shop” for regular failures, low availability levels, or high costs of
Reliability programs, for both new and existing projects. maintenance. For us it’s a challenge, for our clients it
We have proven success on RAMS studies for significant often means millions of dollars impact to their bottom
new projects where our Reliability experts develop line. Increasingly, we are being asked to perform
whole-of-project models including design verification, RAMS studies at the preliminary design stage of major
maintenance plan optimisation, budget forecast, projects. This allows us to build lifecycle models that
risk evaluation, resource requirements, auto loading support proactive reliability, and ensure that asset
plans and matching technical work plans to Asset management systems are set up appropriately with
Management Systems. plans, task instructions, reporting codes and good
functional hierarchies.
Our ability to model real world asset performance
and identify optimal maintenance and logistics It also enables meaningful performance measures to
arrangements has been employed by utilities, rail and be defined to enable targets and thresholds to be set,
power generators to improve asset management and alerting asset performance managers of deviations
demonstrate improvements to owners, regulators and before the asset falls into reactive maintenance mode.
internal stakeholders. Our people love the challenge
of turning around plant that is not performing due to
6

7. Our Clients
Our clients come in all shapes
Key Differentiators and sizes and from a diverse
What differentiates ARMS Reliability from other Reliability range of industries and
service providers?
disciplines.
> People who are experienced, qualified, passionate and highly
expert in Reliability methods.
BHP Iron Ore Asset Reliability 2009-2010
> Isograph software: The most powerful RAMS software tools on
the market.
BHP Potash
Blair Athol Coal
> Integration of RCM with Asset Management Systems: SAP,
Maximo, Ellipse. BMA Coal
> Efficient work methods proven over multiple clients and industries. BHP Illawarra Coal
Collohausi
> Knowledge availability through extensive libraries of failure data,
and maintenance templates. Rasgas
> Proven training excellence. Qatar Petroleum
> Success in small and large project completion. Dalrymple Bay Coal Terminal
Peabody Energy
> Success built on long term customer relationships.
Anglo Gold
BHP Olympic Dam Expansion
What our clients say about us Alcoa
“ Have engagedsuccessesour business globally with huge Business
Improvement
ARMS in
through delivering reliability,
Nyrstar
Sydney Water
productivity and safety
“ SA Water
Watercare
“ In terms of Asset aReliability processesnot hesitate in engaging
improvement, as business we would
and business
Brisbane Water
“
ARMS as a partner Metro Water District Of
Southern California
“ TheofARMSsites where engaged. Withhas deliveredand the way ARMS
all our
team is professional and
past results
results across Snowy Hydro
Portland General Electric
conduct their business engaging our people, I would have no hesitation
Avista
recommending ARMS to others
“ Vline
Qld Rail
“ My experience when using ARMS is that the ARMS team has delivered
positive valued results at each site where engaged and in particular to a EDI Rail
very high standard
“
7

8. “ EMPOWERINg
CLIENTS TO MAkE
bETTER ASSET
“
dECISIONS.
8

9. SERVICES
SERVICES
ARMS Reliability provides expert services in the following
areas, encompassing all phases of asset life cycle for both
new and existing plants.
We focus on empowering our clients with the knowledge and expertise to respond to critical
questions about their plant performance across a full range of related disciplines.
Root Cause Analysis Facilitation ARMS Reliability boasts a track
record of success in partnering
> How do I find the best solution to prevent an
incident recurring? clients to achieve their design,
maintenance and performance
> How do I reduce systemic causes impacting defects?
objectives. Our portfolio is cross-
Incident Investigation platform and cross-industry,
How do I investigate a major incident? including sizable and complex
projects such as:
RBD Simulation Modelling
> Major expansion of iron ore
> Will my design deliver production objectives? handling facility
> Where are the critical bottlenecks which impact > Major expansion of coal handling
production capacity? port facility
> Will my maintenance plans support the Plant > Construction of greenfield
Availability Target? alumina refinery
> What level of spares is cost effective to hold? > Capital planning development for
water and power utilities
RCM Analysis > Assessment of maintenance plan
> How do I develop maintenance plans for new for major hazardous facility
equipment or existing equipment? chemical plant.
> What Spares will I need? > Optimisation of maintenance plan of
> What labor resources do I need? mining shovels and trucks
> Maintenance plan Evaluation > Construction of mega-project to mine
copper and uranium
> Am I performing sufficient maintenance?
> Evaluation of availability of large
communications systems for land-based and
Maintenance Plan Optimisation marine warning systems
> How can I reduce maintenance costs? > Optimisation of maintenance plan of power
> How can I improve reliability? generation
> How can I improve availability? > Identification of “bad actors” of production
> Capital Requirement Forecasting facility and facilitate solutions.
> What capital do I need to budget over the > Development of zero-based budget for
dairy industry
next 10 years?
> Development of libraries for templating
Life Cycle Cost Calculations a large utility.
What is the total life cycle cost of this project in
today’s dollars?
9

10. CASE STUDY: 1
Sydney Water – RCM and RBD Modeling
Sydney Water is currently undertaking an The RCM modelling exercise will deliver the
Sydney Water – RCM andfollowing features:
Rbd Modeling
enterprise-wide drive to create a sound, consistent
and rational system on which it can confidently
> capacity to identify, quantify and prioritise the
base its business decisions. As a critical part of
risks associated with equipment failures
this initiative, Sydney Water has engaged ARMS
Reliability to assist in building a reliability/ > standard sets of meaningful maintenance
maintenance system that enables logical, auditable tasks that can be consistently applied across
and justifiable business decisions related to relevant assets
asset performance. The RBD modeling exercise will provide
capacity to:
This will be accomplished by creating RCM and
RBD models of its critical Sewer Treatment Plants, > forecast availability system performance
Sewer and Water Pump Stations.
> quantify plant risks, such as environmental
licence breaches.
CASE STUDY: 2
Fonterra Edendale - Maintenance Strategy and Critical Item Review
Fonterra Cooperative Group, New Zealand’s largest We also developed a reliability block diagram (RBD),
company (by turnover), handles over a third of all providing criticality analysis of capacity and availability
international dairy trade. during the design phase.
In September 2009, it commissioned the world’s biggest The combination of the RCM-based maintenance
milk dryer, capable of producing hundreds of tons of strategies and the RBD provided a quantitative analysis
milk powder per day. platform from which capital and operational planning
decisions continue to be made
ARMS Reliability was engaged to provide a focused
asset management approach to the new plant during
the design and construction phase and developed all
the RCM-based maintenance strategies ensuring that
the asset was operated safely, risks and costs were
minimised and production maximised.
10

11. EMPOWER EDUCATE EQUIP
CASE STUDY: 3
How Portland General Electric Used RCM to change their maintenance culture
Portland General Electric (PGE) serves over 800,000 generator and an ammonia system. Each was selected to
customers within a 4,000-square mile service area, including assist in the development of an optimised asset strategy
52 Oregon cities. and to promote the benefits of RCM in achieving proactive
maintenance.
In 2006, PGE undertook a program to shift its maintenance
culture and to create a culture of proactivity. The culture change is an ongoing process but with the solid
commitment of all stakeholders, it is achieving its goal.
Using facilitated RCM studies and training, ARMS Reliability
engaged with key stakeholders from PGE including a small
group of employees who undertook a 3 day intensive training
workshop.
The workshop centred on the RCM method of maintenance
task optimisation. The participants learned about the use of
failure data analysis and forecasting that reduce the costs
to their business. This was the first step in promoting a
proactive maintenance culture.
The results of a series of brief RCM studies at different PGE
generating sites were presented to the plant managers and
while impressive per se, they particularly enabled promotion
of the benefits of a proactive maintenance culture.
The argument that “RCM will not work here” or “proactive
maintenance is not for us” can no longer be sustained.
Since the initial studies, PGE has conducted others on a
boiler feedwater system, a circulating cooling water system,
a hydro generating power train, a heat recovery steam
11

12. “ INTERACTIvE,
HANdS ON, PRACTICAL
TRAININg TO EdUCATE
“
RELIAbILITy TEAMS.
12

13. TRAINING
For over 10 years industry has trusted ARMS Reliability to
help improve the skills, knowledge and expertise of their
human resources. ARMS Reliability delivers practical,
hands-on courses to help you learn how to implement
a wide variety of Reliability, Availability, Maintainability
TRAINING
and Safety (RAMS) methodologies into your organisation.
Our courses are interactive and our teaching approach is to promote learning by experience.
Students leave our training courses empowered with confidence, educated with valuable
insights and equipped for effective decision making to reduce risk and maximise the reliability
and availability of their assets.
We offer training courses through either
public or in-house delivery in the following subjects:
> Reliability Centred Maintenance > System Availability Analysis
> Root Cause Analysis > FaultTree Analysis
> RAMS Analysis > Reliability Methods
> Plant Modelling > Hazop Studies
> Incident Investigation > CMRP Exams
> Implementing your RCM > Life Cycle Costing
or RCA program
> Reliability Excellence
13

14. Who should attend ARMS Reliability training?
Design Engineers … who are looking to Maintenance Practitioners … who are
use reliability analysis tools to improve the looking to introduce an effective continuous
reliability of design. improvement strategy and involve the
workforce in improved decision
Asset Managers … who are looking to set
making methods.
up their work management system in a way
that provides for continuous performance Safety Managers … who need to investigate
improvement over the life of an asset incidents, reduce the risk of injury and
or plant. improve workplace safety.
Reliability Managers … who are looking to General Managers, CEOs and Executives …
improve the performance of their assets who want to understand how to maximise
whilst ensuring efficient use of resources. business performance, increase output,
and improve organisational profits and
Maintenance Planners … who need to
shareholder value.
improve maintenance plans and resource
arrangements.
Risk Managers … who need to optimise
activities against the risk of failure and
catastrophic incidents.
14

15. PROBLEM SOLVING
Course Title Features and details Who Should Attend Duration Delivery mode
and Class Maximum
RCA 101e fundamentals of Apollo those seeking 2 hours online
problem solving refresher training or
Apollo eRCA located in remote areas
computer-based training course,
with registrants receiving
12 months online access to
course materials
RCA 102 provides the knowledge and skills operators, maintainers, 1 day / 25 max. public or
necessary to effectively utilise safety representatives in-house
Apollo RCA
RCA and participate in problem
Participant
analysis
Course
developed to equip anyone who
might participate in an accident
investigation, or who needs to
become a better problem solver
(but will not be asked to facilitate
an investigation)
RCA 201 beneficial for anyone whose job engineers, planners, 2 day / 25 max. public or
includes problem solving supervisors and lead in-house
Apollo RCA personnel
Practitioner all participants receive copy of (laptop an
Course Realitycharting software advantage)
RCA 301 for facilitators with 6-12 months trained facilitators 1 day / 15 max. in-house
experience; aimed at improving
Apollo RCA skills in applying the method and
Super User ensuring success
Course
RCA 401 for managers and supervisors not department managers, 0.5 Day / 15 max. in-house
involved in the details of incident superintendents.
Apollo RCA
investigation, but having the need
Managers
to direct associated activities
Course
course can also be used as an
overview for anyone interested in
effective problem solving
RCA 501 tracking corrective actions and those responsible 1 day in-house
analysing failure data for effective failure
Failure elimination
Reporting
II 101 basic incident investigation anyone required to 2 days public or
management manage an incident in-house
Incident
Investigation
15

16. RELIABILITY TRAINING
Course Title Features and details Who Should Attend Duration and Delivery mode
Class Maximum
REL 101 failure rates, FMEA, FMECA, RBD, RCM, FaultTrees, engineers who 1 day / 25 max. public or
Reliability LCC, failure reporting require an overview of in-house
Roadmap reliability methods
REL 102 workshop with exercises illustrating how to move a anyone seeking a 2 days / 15 max. public or
system from Reactive behavior to Proactive behavior more effective way to in-house
Managing
using Reliability Methods. make and integrate
Reliability
maintenance decisions
Improvement covers introduction to Weibull Analysis, FMEA, RCM,
RBD, and LCC.
participants make decisions in a simulated
environment, compare the benefits, and learn how to
evaluate maintenance decisions against impacts.
no computers required.
participants download demo’ version of RCMCost and anyone interested in 2 days public
RCM 101 learning how RCM
are introduced to maintenance decision making using
Managing RCM simulation software computer
RCMCost.
using RCMCost can assist them and demo’
participants receive booklet with typical reports out software
of RCMCost, including a maintenance plan and work essential
instructions.
RCM 201 maintenance optimisation using RCM and life cycle RCM team 3 days / 12 max. in-house
Maintenance simulation. members involved
Optimisation in a maintenance computer
skill-building course on how to use RCMCost: and licensed
o Weibull data analysis. improvement study
software
o risk/cost benefits analysis. essential
o maintenance task optimisation
o plan development.
RCM 301 advanced features that allow more accurate requires completion 2 days / 15 max. in-house
ADV Software emulation of reality: of RCM 201 and
computer
Features and o hidden failures experience as an RCM
and licensed
Manipulation o redundancy factors team member
software
o operating time factor
essential
o risk and criticality
o P-F distributions
efficient use of RCMCost inputs and outputs:
o data mapping
o producing work instruction documents
o scenario comparison.
o maintenance cost prediction
o safety criticality
RBD 301 system analysis using Reliability Block Diagrams: team members, 2 days / 15 max. in-house
Plant Availability o parallel and series dependencies process engineers,
o redundancy maintenance engineers computer and
Simulation
o importance ranking, licensed
o spares inventory holding software
o “what if” scenario analysis essential
RBD 401 Plant Capacity Determination: process engineers, 1 day / 15 max. in-house
Advanced Plant o process flow analysis maintenance engineers
computer and
Availability o determining capacity
licensed
Simulation o identifying bottlenecks
software
o aligning shutdowns
essential
o “what if” scenario analysis
o criticality analysis of complex systems
LCC 401 life cycle costs calculation: project, plant 1 day / 15 max. in-house
o cost tree development including sustaining and maintenance
Life Cycle Cost and acquisition costs engineers, involved in computer and
Calculations o time value of money asset selection and licensed
o rate of return and alternative scenario repair or replacement software
comparison decisions essential
16

17. Course Title Features and details Who Should Attend Duration Delivery mode
and Class Maximum
FTA 201 quantitative risk analysis using fault trees safety engineers, risk 2 days / 15 max. public and
Fault Tree and event trees: managers, instrumentation in-house
Training o initiator events or control engineers
computer
o enabling events designing level of
and demo’
o importance analysis protection.
software
o event tree
essential
o scenario analysis
HAS 201 HASOP studies: team members involved in 1 day / 15 max. In-house
Hazops o key words hazard assessment
computer
o setting criteria
and licensed
o risk matrix
software
o hasard ranking
essential
REL 401 advanced asset reliability management: leaders accountable for 1 day / 15 max. public or
Reliability o key performance indicators asset reliability, program in-house
Leadership o visible reliability features sponsors
o brown field/greenfield modelling
practices
o reliability input to new projects
REL 402 managing optimisation studies for team leaders of RCM or 1 day / 15 max. in-house
Managing maintenance, plant availability, LCC: reliability improvement
computer
Reliability o facilitating projects teams
and licensed
Projects o data collection
software
o model quality review
essential
o Pareto analysis
o roles and responsibilities
o presenting project overviews
o project completion reports
50x specialist courses on specific equipment: trained members of RCM 1 day / 15 max. in-house
Specialist o conveyors teams or industry
Courses o mobile plant networks
o electrical gear
o instrumentation
o crushing and grinding circuits
Workshop designed for experienced reliability experienced reliability 4 days / 15 max.
Expert Reliability practitioners who want to expand their practitioners (plus CMRP exam on
knowledge base further, or extend their 5th day)
skills in facilitating and conducting
reliability studies
17

18. “ POWERFUL
SOFTWARE TO EqUIP
yOU WITH THE RIgHT
dECISION MAkINg
TOOLS.
“
18

19. SOFTWARE
ARMS Reliability sells, supports and implements the
Isograph Suite of Reliability Software which empowers
businesses to optimise the reliability, availability,
maintainability, safety and risk in industries such as rail,
nuclear, automotive, aerospace, mining, manufacturing,
utilities, power generation, oil and gas, and defence.
All software licences are available as network or stand alone installations to allow
maximum flexibility. Technical data sheets are available for each product on request.
The software suite comprises the following products:
> Availability Workbench
Reliability Centred Maintenance,
Availability Simulation, Life Cycle Costing, > Hazop+
Weibull Analysis. Hazard and Operability Analysis for
Operators, Engineers and Management
> Reliability Workbench
Prediction, FMECA Studies, Reliability Block > NAP
Diagrams, Fault Trees, Event Trees and Reliability and Availability Analysis for
Markov Analysis Communications Networks
> FaultTree+ > FRACAS+
Event Trees, Markov and Fault Tree Analysis Software FRACAS Software for Collecting, Recording
and Analysing Failures
> LCCWare
SOFTWARE
Life Cycle Cost Analysis for Evaluating the Whole Life > AttackTree+
Cost of a System Attack Tree Analysis Software for Modeling
Threats against System Security.
19

20. AVAILABILITY
WORKBENCH
Availability Workbench is a powerful, integrated
software package that combines RCM with
Availability Simulation, LifeCycle Costing, Data
Analysis and integrates with corporate ERP
systems, databases and CMMS software through
an analytics portal.
ARMS Reliability have worked in conjunction
with Isograph, the software developers, to keep
these products at the forefront of essential
reliability decision making tools .
ARMS Reliability have implemented
Availability Workbench on many major
projects in the resource sector, power
generation and capital intensive industries
since 1997.
Availability Workbench performs all the
Reliability Analysis neccessary to meet
everyday needs, as well as perform
RAMS on each phase of a large project.
20

21. Availability Workbench provides a fully
integrated environment for:
> Reliability Centred Maintenance: > Availability Simulation:
Developing and maintaining a Reliability Performing full system availability and
Centred Maintenance (RCM) program to capacity predictions utilising Reliability
optimise your reliability and maintenance Block Diagrams (RBD) that take into account
strategy; supports RCM standards such as complex dependencies on spares and other
SAE JA1011, MSG-3 and MIL-STD-2173(AS). resources.
> Weibull Analysis: > Life Cycle Cost Analysis:
Analysing historical failure data from the Performing a Life Cycle Cost Analysis to
CMMS to model the failure characteristics calculate the expected costs of your system
of equipment. during its lifetime and model repair versus
replace decisions.
> Enterprise Reliability Portal:
Integrating the reliability decision making
tools with the CMMS to enable easy data
transfer. It boasts a powerful analytics
portal to the CMMS enabling graphic
analysis of plant performance to initiate
decision making.
21

22. WHAT AVAILABILITY
WORKBENCH EQUIPS
YOU TO DO
Asset Hierarchy Develop an asset hierarchy that drills down into systems and subsystems
to maintainable items. Use for RCM studies or load to CMMS.
Criticality Assign a criticality rank for each maintainable item. Define criticality
thresholds to automatically assign criticality based on simulated
results. Automatically assign criticality based on Work Order history.
Can be used to check/validate initial rankings.
FMEA Generate and print a list of Functions, Failures, Failure Modes and
Effects for each maintainable item hierarchy.
FMECA Rank failure modes by criticality in order of cost, safety, operational
impacts. View a Pareto chart of predicted effects and dominant
failure modes.
Failure data Analysis Analyse sets of failure data and fit to curve of best fit. Where no
data exists, assign representative parameters or use a wizard to
define appropriate parameters. Update parameters as they become
available from work order system.
Optimise Maintenance Determine optimal maintenance task and frequency that gives lowest
total cost or risk.
group Tasks Group individual tasks to form a job or job plan. Optimise groups to
check for the optimal grouped interval.
22

23. Simulate Scenarios Simulate alternative strategy scenarios comparing run to
fail, existing plan versus optimised plan. Can also evaluate
alternative design, level of redundancy and repair versus
replace options.
Produce Plan Print the optimised plan identifying tasks, labor, spares,
duration, frequency, maintenance effectiveness, and
electronically load to CMMS through file import/export or directly
to SAP/Maximo/Ellipse through the portal.
Predict Resources Predict spares usage and labor requirements for both planned
and unplanned maintenance. Planned maintenance includes all
inspections, monitoring, refurbishments, shutdown plans, and
capital replacements.
Zero based budget Print budget requirements.
Risk Profile Identify risk exposure and major contributors. List any risks that exceed
threshold levels.
Utilise Libraries Drag and drop from and to library.
Repair or Replace Optimise when you should continue to repair the asset or invest
in with a replacement.
Assess Availability Convert FMECA to Reliability Block Diagram and arrange logic to reflect
system design including redundancy. Can link FMECA to RBD so changes in one
will update predictions in the other.
Assess Life Cycle Costs Draw cost predictions into Life Cycle Cost module and simulate costs.
Update Input latest Failure data and re-simulate to identify any changes to
optimal strategies.
23

24. RCMCOST
MODULE
RCMCost is a maintenance simulation module of Availability Workbench
that allows maintenance tasks to be evaluated over a lifetime. Allowing
for ageing over a lifetime, the package calculates the cost of failure
modes comparing the benefit against alternative strategies. It’s an
empowering tool for maintenance practitioners who need to optimise
maintenance activities against the risks of failure, and to predict future
costs and performance levels. This package brings maintenance decision
making into the “information age”.
RCMCost supports Reliability Centred Maintenance standards such
as SAE JA1011, MSG-3 and MIL-STD-2173(AS) by providing a structured
method for entering FMECA data and simulating the effects of different
maintenance strategies on cost, safety, the environment and
operational issues.
The RCM decision making process is therefore substantially enhanced by
the ability to quickly simulate the effects of preventive tasks, inspection
tasks and condition monitoring taking into account ageing, hidden
failures, maintenance crew costs, spares costs, availability and more.
This extremely powerful package is valuable as a preliminary first pass
or as a part of an ongoing continuous improvement program. It can be
used to capture and preserve engineering knowledge and to provide
a quantitative means of updating strategies from work order history.
RCMCost uses the language of the business (that is, dollars and risk) to
support maintenance decision making.
RCM is a procedure for determining maintenance strategies taking into
account the prime objectives of a maintenance program:
> Minimise Costs
> Meet Safety and Environmental Goals
> Meet Operational Goals
24

25. The RCM process begins with a failure mode and effects
analysis which identifies the critical plant failure modes in a
systematic and structured manner. The process then requires
the examination of each critical failure mode to determine the
optimal maintenance policy to reduce the severity of
each failure.
This decision may include combinations of:
> Scheduled Preventive Maintenance Tasks
(Lubrication or Replacement)
> On-Condition Inspections
> Inspections for Hidden Failure
> Condition Monitoring Alarms
> Re-Design
The chosen maintenance strategy must take into account cost,
safety, environmental and operational consequences. The effects
of redundancy, spares costs, maintenance crew costs, equipment
ageing and repair times must be taken into account along with
many other parameters.
Once optimal maintenance policies have been recorded the RCM process provides
plant performance predictions and costs, expected spares requirements and
maintenance crew manning levels.
The powerful reporting tool within Availability Workbench empowers the user to
create many reports to represent the results of the RCM analysis.
The RCM process can be
used to develop a living
strategy with the plant
model being updated
when new maintenance
history is available or
design changes take place.
The ERP module of the
Availability Workbench
equips the user to
seamlessly update the
CMMS with the resultant
RCM maintenance strategy
and analyse maintenance
history as it accumulates.
25

26. AVSIM MODULE
A sophisticated Monte Carlo simulation The AvSim module can help you optimise
package for analysing plant availability asset availability and life cycle costs
and reliability using Reliability Block by modelling:
Diagrams (RBD). The AvSim+ Monte Carlo
> Plant availability and throughput
simulator engine is the result of 16 years
> Planned and predictive maintenance
of evolutionary development. The simulator
policies from RCMCost
enables AvSim+ to model complex
redundancies, common failures, ageing and > Shutdown intervals
component dependencies which > Spare part tracking and stock-out
cannot be modelled using standard > Equipment switching delays
analytical techniques.
> Tank storage levels
> Seasonal operations
> Duty/Standby systems
Apply the Reliability Block Diagrams
to make the logical connections which
describe your plant and equipment
arrangements, and the program will
automatically deduce the failure logic of
the system.
Once you have defined the logical
structure of your project you can define
comprehensive failure and maintenance
models to represent the performance
of components within your plant. These
models could be simple failure and repair
models or they could represent complex
dependencies including ageing, spares
requirements, labor availability, operational
phases and standby arrangements.
26

27. Consequences are then assigned to any level of the logical diagram
to indicate the effects of failures (financial, operational, safety and
environmental). Labour, spares and failure data may be imported
or directly entered into the program together with any operational
phase information and task group assignments.
The AvSim module may be used to simulate the effects of different
spares holding levels on lifetime costs. The user sets site and
depot minimum and maximum values for all selected spares.
When performing a spares optimisation run AvSim will try spares
holding values within the specified range only.
The program performs simulation runs for each combination of
spare part holdings (between range values) for each selected spare
part. Once all the simulation runs have been completed AvSim will
display the optimum spares holdings from a cost viewpoint at site
and depot.
The AvSim module may be used to determine whether it is
worthwhile performing planned maintenance or inspections on
components, and if so, what the optimal shutdown or turnaround
interval should be.
If a component exhibits ageing characteristics then planned
maintenance may be effective in reducing the probability of a
system outage and hence reduce outage costs. However, the
planned maintenance task may have labour, spares and other
costs associated with it. Planned maintenance costs must be
balanced against reduced outage costs.
Similarly, performing inspections for hidden or potential failures
will often reduce costs due to unscheduled outages. The benefits
of reducing the costs of unscheduled maintenance need to be
weighed against the additional costs of performing more frequent
inspections. The AvSim module locates the optimum interval
for planned maintenance and inspection tasks by varying the
maintenance interval and repeatedly simulating the lifetime costs.
27

28. ENTERPRISE
RELIABILITY PORTAL
The Enterprise Reliability Portal (ERP) links a company’s Upload Maintenance Plans
Enterprise Asset Management or CMMS to the Availability
Workbench software. This provides Maintenance and The Maintenance Plan module of the ERP enables
Reliability Engineers with a real-time decision making tool, you to transform optimised maintanance strategies
utilising maintenance history to optimise maintenance directly into your CMMS from the RCMCost module of
strategies through the use of advanced and mature reliability Availability Workbench.
simulation tools.
It gives you the ability to:
The ERP allows you to create a “living program” through
> Highlight new maintenance strategies that are ready
the alignment of data captured in the CMMS with to load to the CMMS
Availability Workbench and provides a continuous reliability > Determine whether tasks in the CMMS have been
improvement process over the asset life cycle. changed and are different to the ones in
Availability Workbench
> Record changes and reasons for change when
they are made
> Create detailed and customised work instruction
documents in Word or PDF format
> Display existing maintenance strategies in CMMS.
28

29. Analyse Plant Performance
The analytics module of the ERP enables a view into the maintenance history in the
CMMS. This module uses a drill down graphical display to allow the user to assess plant
performance and analyse areas where improvements can be made to initiate decision
making in Availability Workbench.
Maintenance history can be viewed for individual equipment or for equipment classes
across the facility. This data can be converted to Weibull sets to analyse for failure
characteristics, reliability growth and the effectiveness of current maintenance strategy.
Handle Master Data
The ERP can transfer the data from the RAMS models to setup and configure the
CMMS system. In a new plant or procured piece of equipment, a RAMS study should be
performed to justify the amount of equipment, amount of redundancy, risk and optimal
maintenance strategy. The information used in these studies is transferred directly to
the CMMS for the operational phase of that plant or equipment to ensure data alignment
between strategy and work management.
Data that is typically loaded from Availability Workbench includes equipment hierarchy,
equipment criticality, equipment classes, failure codes, spare parts and bills
of materials.
Build RAMS Models
Where there is existing data in the CMMS, it can be used to build a RAMS model utilising the ERP to extract the necessary information to map to
the Availability Workbench tables and fields. This process minimises time spent in data entry, freeing up engineers to focus more on analysis.
Maintenance history can be viewed for individual equipment or for equipment classes across the facility. This data can be converted to
Weibull sets to analyse for failure characteristics, reliability growth and the effectiveness of the current maintenance strategy.
29

30. THE LIFE CYCLE
COST ANALYSIS
MODULE
Life Cycle Cost analysis is used to evaluate the through-life cost of new plant or equipment. The user
builds a hierarchical Cost Breakdown Structure (CBS) through an unlimited number of indenture
levels starting at the conception stage and continuing through research and development, design,
operations and maintenance and ending with system disposal.
The items may be further subdivided until the cost of each element can be defined as a mathematical
equation. At a simple level this can be the number of man-hours multiplied by a cost rate. The
elements of cost will then be added together to give the total cost for each item and a grand total for
the system through its full life.
The CBS can be directly linked to cost predictions produced by the RCMCost or AvSim modules. Other
costs may be defined as time-dependent cost equations or simple numerical values. Global variables
may be defined and utilised in the cost equations.
High level costs are determined either by summating the cost values for child nodes in the CBS or
by applying a user-defined cost equation. The syntax of cost equations is easy to understand and the
construction of cost equations is assisted by an intelligent code recognition utility that automatically
reveals global variable lists as the user types in an equation. Phase-dependent cost equations can
also be defined. Phases are shared between the LCC and AvSim modules.
The LCC module allows users to define life cycle costs other than those predicted by the RCMCost
and AvSim modules. These costs may be integrated with predicted costs in the LCC cost breakdown
structure to provide a time-dependent analysis of a system’s whole life cycle cost process.
30

31. WEIBULL
MODULE
The Weibull Analysis module of Availability Workbench analyses historical failure and repair
data by assigning probability distributions which represent the failure or repair characteristics
of a given failure mode used during an RCMCost or AvSim system simulation.
The Weibull Analysis Module analyses times-to-failure and time-to-repair data using the
following distributions:
> Exponential Distribution > Lognormal Distribution
> 1-Parameter Weibull Distribution > Normal Distribution
> 2-Parameter Weibull Distribution > Weibayes
> 3-Parameter Weibull Distribution > Phased Bi-Weibull
> Bi-Weibull > Phased Tri-Weibull
> Tri-Weibull
The Weibull module automatically fits the selected distribution to the data provided and displays the results
graphically in the form of cumulative probability plots, unconditional probability density plots and conditional
probability density plots. The plots may be viewed on the screen or printed to a report.
31

32. NORTH AMERICA
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Fax: +61 3 5255 5778
Email: info@globalreliability.com
www.globalreliability.com