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Asset Reliability Programs

An asset reliability program is a set of pre-planned work for an asset (work standards). In APM, this includes standard tasks, standard jobs, and preventive maintenance routes. You can include triggering rules that define when the work is to be done. Using APM, you can define, implement, and manage effective, proactive reliability programs.

This topic discusses general concepts related to asset reliability programs. For information on specific elements, see the following topics:

•	Work Standards

•	Work Triggers

•	Indicators, Types, and Value Categories

•	Introduction to Calculated Indicators

•	Work Templates

Setting up an Asset Reliability Program

Standard tasks describe work that needs to be carried out on a piece of equipment over its lifetime to keep it in good operating condition. Many of the tasks contained in the asset reliability program, such as preventive maintenance work, are designed to be performed on a regular basis according to established time or usage intervals. The program can also contain work that needs to be carried out when specific indicators of asset health or condition demand it.

You can group standard tasks into work packages called standard jobs. Each standard job can then be triggered to create a work order. You can create work orders from standard jobs manually, as a way of acknowledging indicator warnings and alarms, or you can have APM trigger them based on pre-defined rules.

When you set up triggering rules for standard jobs, you are telling APM when the work should be done on the asset. When the conditions in a triggering rule are met, APM creates a work order from the standard job. You can base triggering rules on time intervals, shutdown types, or on the state of asset indicators.

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Using an Asset Reliability Program to Plan Work

Once you have created a reliability program for your assets, you can use it to create and plan work orders. You can:

•	Create work orders manually from standard tasks and standard jobs whenever necessary

•	Acknowledge indicator warnings and alarms by creating work orders from standard jobs

•	Have APM automatically create work orders from the standard tasks and jobs based on triggering rules

You can use standard jobs to manually create work orders. For example, there might be work that could be performed whenever a production line switches from one product to another. While you could tell APM when the turnover was about to occur through shutdown codes or possible asset indicators, in many cases it would cost too much to maintain this information. It might be easier to manually create the work order from the standard job when production tells maintenance that the turnover is about to occur.

Triggering Rules

Triggering rules tell APM when to create work orders from a standard job or preventive maintenance (PM) route. For example, you might define a triggering rule for a standard job that says “trigger every 30 days OR every 2000 miles.” You can create a triggering rule for each standard job or PM route.

You can create rules using a combination of conditions. Conditions can be based on:

•	A time-based frequency (for example, every 30 days)

•	A shutdown occurrence (for example, the Annual shutdown)

•	A cumulative measurement (for example, every 2000 miles or when the vehicle reaches 50,000 miles)

•	The asset’s operating condition (for example, when the temperature exceeds 100o or when the pressure is less than 10 PSI)

Put these conditions in a triggering rule using rule clauses. For example, the rule “trigger every 30 days OR every 2000 miles” uses two rule clauses: every 30 days and every 2000 miles. When one of those clauses is true, the work order is generated from the standard job.

Future-dated Work Orders

You can create future-dated work orders from standard jobs that have time-based triggering rules. This allows you to manage a backlog of work orders.

You will set the horizon date for the future-dated work orders. Based on the date that you enter, APM creates the appropriate number of work orders for the time interval in the triggering rule.

For example, the triggering rule says that a work order should be created from the standard job every week. Today is May 1 and you enter a horizon date of May 29. APM creates four work orders:

Work Order	Start Date
1	May 8
2	May 15
3	May 22
4	May 29

When you generate future-dated work orders, a results dialog shows what work orders were created. You can then schedule the work order tasks and execute the work from those work orders.

Sometimes the start date of a work order depends on when the previous work order was completed. If this is the case, APM updates the start date for future work orders when the previous one is marked as closed.

For example, APM has created four work orders. The first work order was closed two days late, so APM adds two days to the start date of the remaining three work orders.

Work Order	Start Date	New Start Date
1	May 8	N/A
2	May 15	May 17
3	May 22	May 24
4	May 29	May 31

This will ensure that there is always a week from the time one job is finished to the time the next is started. You can tell APM to do this by setting up a triggering rule with a “variable” time trigger.

Early-warning Rules

When you set up a triggering rule, you can add an early warning condition to it. For example, if you have a job that needs to be done every three months, you can have APM warn you five days before the job is triggered. To do this, add an early warning condition to the rule clause.

If you want, you can have APM trigger a work order when the early warning condition is valid. When you enter indicator readings or generate future-dated work orders, APM also checks the early warning conditions to see if there is any work that will be triggered soon. You can review these “early warning” jobs, and if you want you can create and plan work orders for them.

Shutdown Types and Shutdown Instances

In APM, shutdown types are used to identify the different types of shutdown periods that occur within a plant or facility. The annual shutdown, spring shutdown, and an area shutdown are examples of shutdown types. Shutdown types do not have specific dates because they can occur multiple times within a year and over multiple years.

You can define and plan individual occurrences of a shutdown. For example, the 2015 annual shutdown can be planned as a separate occurrence of the annual shutdown type.

A shutdown record communicates to planners the equipment and tasks involved in a specific shutdown period. You can associate a shutdown with start and end dates, shutdown type, assets, standard tasks and jobs, and work order tasks. When PM work is generated for a shutdown type, the generated work orders are assigned to the next shutdown associated with that shutdown type.

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Swappable Components

If your site uses components and component locations, you can create an asset reliability program for the component asset or for the component location asset. Usually, you will create the program on the component location asset. This way, the program will apply no matter which component is installed there. In this case, the reliability program will reflect the context of the location (or place) that the component is installed. If there are tasks that are specific to the component itself, (such as rebuild tasks) then you should include them in the components program.

If you set up the program on the component, APM copies the work history to the location. If you set up the program on the location, APM applies it to the installed component. Further, when work orders are triggered from standard jobs written to the location, the work order is created with the component as the asset to work on.

When you swap components, the program can be restarted for the new component or location. All time-based triggers start tracking time from the date that the swap occurred. Asset indicators can also be reset. For example, if you swapped a motor that needs a vibration analysis every three months or 400 operating hours, the triggering rule would start counting to three months from the date the swap occurred and the indicator that tracks operating hours would restart its count to 400.

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