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Overview of Performing Maintenance Task Analysis

Performing maintenance task analysis involves defining the causes and effects of the assets’ functional failures, performing risk analysis, if required, and developing action plans to prevent or mitigate failures. You can use APM MTA2 tools to record analyses as they are performed by the team. Performing an analysis involves the following tasks. Links are provided to topics that explain each task in detail.

Create the Analysis and Select Assets

Starting the maintenance task analysis involves selecting the primary asset to be analyzed, with or without its descendants. Analyses can be performed on all types of assets except components. You can create the MTA2 from scratch or from a template. You can select an analysis type (a set of predefined options), change the default analysis type, or select options manually.

For more information:

•	Creating an MTA2 from Scratch

•	Creating an MTA2 From a Template

An analysis can also be created from an analysis request. For example, when an inspector reviews an indicator reading and decides that a failure mode review is required, the inspector can create a request for a strategy development analysis. When the request is processed, the analysis is created or updated. Information from the request is copied to the analysis: the requested start and completion dates are copied to the planning information on the General tab’s, Details tab. The Analysis Requests tab shows information about the original request.

It is a good idea to review a new analysis’ settings to ensure that they are appropriate for the asset and process. For more information:

•	Setting Failure Mode Options for an MTA2

•	Setting Risk Analysis Options for an MTA2

As the analysis progresses, you might wish to add assets to the analysis hierarchy that you identified when creating the analysis. You can also change the primary asset on an analysis, update the analysis hierarchy, and renumber assets.

For more information:

•	Adding Assets to an MTA2

•	Renumbering Assets and MTA2 Failure Modes

•	Changing the Primary Asset on an MTA2

•	Updating the Asset Hierarchy Snapshot for an MTA2

In some cases, assets are large enough to warrant separate analyses for different sections. For example, when the top portion of a large vessel contains gas and the bottom holds liquid, separate analyses or failure modes are needed to define and respond to different failure modes and effects. In this case, you can provide a description of the analysis scope. The same asset can be added to the analysis as many times as required, each with a difference scope description.

For more information, see Working with Asset Scope on an MTA2.

Record the Primary Asset’s Operating Context

The analysis team will find it helpful to define the circumstances in which the assets operate before they develop failure modes and action plans. Recording the operating context in APM involves selecting a brief description from the list of supplied values and then entering the detailed operating context statement, including how and where the asset is used and the performance criteria that apply to output, throughput, safety, environmental integrity, and so on.

For more information, see Recording the Primary Asset’s Operating Context for an MTA2.

Manage the Analysis

APM provides tools to help you manage the analysis project, from recording team members, to documenting meetings, to recording comments. For more information:

•	Adding Team Members to an MTA2

•	Entering and Reviewing Comments on an MTA2

•	Recording Team Meetings on an MTA2

•	Working with the MTA2 Checklist

Add and Analyze Failure Modes

Create or copy one or more failure modes and failure effects. A failure mode is a single event that causes an asset to fail to perform its function. For example, if a pump’s impeller becomes worn, the pump cannot convey liquid at the required rate. A failure effect is the result of a failure mode. For example, when a pump’s impeller becomes worn (failure mode), the flow through the pump declines until it no longer delivers liquid at the required rate.

The next step in developing the failure modes is to select a recommended action from the list provided:

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Scheduled Restoration/Discard: Scheduled restoration entails restoring the initial capability of an existing asset at or before a specified age limit, regardless of its apparent condition at the time. Scheduled discard or replacement tasks entail discarding an asset at or before a specified age limit, regardless of its condition at the time.

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Condition-Based Maintenance entails checking for potential failures so that action can be taken to prevent the functional failure or to avoid the consequences of the functional failure. On-condition tasks are so called because the items that are inspected are left in service on the condition that they continue to meet specified performance standards.

•	Failure-Finding Maintenance involves checking a hidden function at regular intervals to find out whether it has failed. The intervals are calculated based on the required availability of the asset and the reliability of the protected function.

•	Modification/Redesign is any one-time change to the equipment, training, maintenance or operating procedures, etc.

•	No Scheduled Maintenance means assets are left in service until a functional failure occurs, at which point they are repaired or replaced.

You can perform failure mode or demand scenario risk analysis, depending on the requirements of the asset. You can also record failure data, especially if you intend to use Isograph Availability Workbench to optimize reliability programs.

Tip: Susceptibility to failure evaluation can also be incorporated into risk analysis. Typically, a questionnaire is used to examine the asset’s non-age related degradation patterns. It can provide an alternative to probability of failure analysis for these failure modes. For example, susceptibility evaluation can be used to determine the vulnerability of atmospheric storage tanks to corrosion under insulation or stress cracking. The evaluation can result in recommended actions, susceptibility ratings, or both.

For more information:

•	Creating MTA2 Failure Modes

•	Creating Analysis Requests for MTA2 Failure Modes

•	Overview of Risk Analysis

•	Evaluating Susceptibility to Failure for MTA2 Failure Modes

•	Performing MTA2 Failure Mode Risk Analysis

•	Performing MTA2 Risk Analysis with Weighted Severities

•	Performing MTA2 Demand Scenario Risk Analysis

•	Viewing Risk Analyses for MTA2 Failure Modes

•	Recording MTA2 Failure Data

•	Recording and Reviewing MTA2 Failure Mode Details

•	Copying MTA2 Failure Modes

•	Renumbering Assets and MTA2 Failure Modes

Using Isograph Availability Workbench

Using the integration functionality in APM, you can export failure modes from analyses in APM to the Isograph Availability Workbench (AWB), where you can analyze and optimize the data. You can then import optimization results into the APM analysis, review the recommendations in the Optimization view, and make appropriate changes to the action plans.

Before you can export failure modes, you must have installed the Availability Workbench with a valid license. Your APM license must include the Reliability Strategy Development and Implementation and Performance Management modules, and the modules must be active on the sites where you want to use the functionality.

For information about using this functionality, see APM Integration Guide for Isograph Availability Workbench.

Develop and Implement Action Plans

You can evaluate the economic feasibility of implementing the proposed maintenance tasks. Then develop the action plans for the selected strategy by describing tasks, determining frequencies, and more.

In some cases, you might need to create secondary action plans for failure modes. For example, a failure mode might require a condition-based maintenance task to check for signs of wear, a secondary modification to procedures (for example, training for maintenance personnel), and scheduled restoration in the future. You can add secondary actions as you are developing the MTA2, or you can add them later.

For more information:

•	Evaluating the Feasibility of MTA2 Maintenance Tasks

•	Developing Primary MTA2 Action Plans

•	Creating Secondary MTA2 Action Plans

•	Calculating a Failure-Finding Interval for an MTA2 Action Plan

Add Inspection Tasks and Indicators to Action Plans

An inspection task is a standard task that lists the indicators to be read to perform an asset inspection. You can add an existing standard task to the action plan or create one from scratch or from a template. When you create an inspection task from scratch, you can add new indicators or specify a dynamic route to collect existing indicators for route assets.

Depending on the type of action, you can create or select indicators to monitor assets for potential failure. When you have developed action plans, you can generate a report that shows how indicators are distributed on standard tasks.

For more information:

•	Adding Inspection Tasks and Indicators to MTA2 Action Plans

•	Reviewing Indicator Collection Information on an MTA2

Add Corrective Tasks, Documents, and Follow-up Work to Action Plans

Depending on the type of action, you can create or select a corrective task to support the recommended action. If the asset is to be modified or redesigned, you can assign a standard document to the action plan. You can also assign work requests and work order tasks for follow-up work.

For more information:

•	Adding Corrective Tasks to MTA2 Action Plans

•	Adding Follow-up Work to MTA2 Action Plans

•	Adding Standard Documents to MTA2 Action Plans

•	Viewing MTA2 Failure Modes for Standard Tasks and Jobs

Add Critical Parts to Action Plans

For all types of analyses and recommended actions, you can add a list of the materials needed to perform the action. Select from the parts catalog or define non-cataloged items, providing their part IDs, names, and quantities.

If you maintain a resource catalog in APM (and interoperability is not enabled for the site), you can select material resources from the catalog.

You can also develop a catalog of parts for use in the site’s analyses.

Note: To use this functionality in APM, you must enable feature 42. In the Enterprise window, select the Customization Center view and the Enabled Features tab. Click Browse, select “Support for critical parts identification on a maintenance action plan”, and click OK. If APM is running as a smart client, click Refresh Enabled Features on the server. Then restart the client to use the functionality.

For more information, see Adding Critical Parts to MTA2 Action Plans.

Monitor the Status of Analyses

Monitor the status of an analysis by reviewing failure modes and marking them “Facilitation Completed” and “Implementation Completed”. When implementation has been completed for all of its failure modes, change the analysis’ status to “Analysis Completed”.

If your organization uses the APM formal approval process, it is typically employed to vet the analysis when implementation has been completed for all failure modes. When the analysis has been approved, you can close the analysis.

You can define action plan task statuses for use with failure modes and action plans in addition to the statuses provided by APM (Facilitation Incomplete, Facilitation Completed, Implementation Completed, and Implementation Not Required). Facilitators and implementers can then use the additional statuses to co-ordinate their efforts, for example, marking an action plan for follow-up or review.

For more information:

•	Changing the Status of MTA2 Failure Modes and Analyses

•	Sending an MTA2 for Approval

•	Working with MTA2 Action Plan Task Statuses

View Information About the Analysis

At any time, you can review analysis summaries or detailed information about an analysis’ status and history. The Analysis Summary view provides information about the analysis’ assets, action plans, indicators, tasks, and jobs. The Implementation view provides a list of action plans, their failure modes, recommended actions, corrective tasks, and indicators. You can also review the reliability programs for the analysis assets.

You can also print several reports from the analysis, including lists of action plan details and failure modes.

For more information:

•	Viewing Information About an MTA2 or Template

•	Reviewing MTA2 Assets’ Reliability Programs

•	Viewing MTA2 Failure Modes and Action Plans

•	Printing MTA2 Reports

Link Action Plans to Projects

When the recommended action is to modify or redesign the asset, you can link the action plan to a project to plan and track the modifications.

For more information:

•	Linking MTA2 Action Plans to Projects

•	Working With a Project’s Links to MTA2 Action Plans

Create MTA2 Templates

A maintenance task analysis template is a group of settings that can be used as the basis for an analysis. You can create MTA2 templates and organize them in a hierarchy.

For more information:

•	Creating an MTA2 Template

•	Setting up a Hierarchy for MTA2 Templates

•	Viewing MTA2 Template Hierarchies

•	Moving an MTA2 Template to a Different Site