Training Manual

Condition Monitoring

Training Manual

Condition Monitoring

Prepared By:Yihang Wang & Darryl Smith

Approved By:

Date:Feb 2015

Table of Contents1.Overview51.1.AMT Overview51.2.Overview of CM61.3.Login and Navigation91.4.Terminology92.Learning Objectives103.Processes123.1.A: Measurements Process123.1.1.Objectives123.1.2.Process Owner123.1.3.Outputs123.1.4.Inputs123.1.5.Process Diagram133.2.B: Inspections Process143.2.1.Objectives143.2.2.Process Owner143.2.3.Outputs143.2.4.Inputs143.2.5.Process Diagram153.3.C: Direct Notification Process163.3.1.Objectives163.3.2.Process Owner163.3.3.Outputs163.3.4.Inputs163.3.5.Process Diagram173.4.D: Live RCM Process184.Procedures (A: Measurements)194.1.1.Configure Measurement Codes194.1.2.Configure Measurement Translation Rules204.1.3.View / Record Measurements (AMT Client)224.1.4.View / Record Measurements (AMT Mobile)244.1.5.Import Measurements from External Systems265.Procedures (B: Inspections)275.1.Setup Inspection Templates275.1.1.Electronic Workscope Manager275.1.2.Inspection Config275.1.3.Inspection Steps285.1.4.Inspection Type295.1.5.Inspection Item Node295.1.6.Inspection Display Modes325.2.Statutory Compliance345.3.Perform an Inspection355.3.1.Select Site355.3.2.Employee Login365.3.3.Select Asset375.3.4.Select an Inspection375.3.5.Select Start Date / Time385.3.6.View / Record Usages395.3.7.View / Record Defects405.3.8.Perform Inspection Steps415.3.9.Inspection Summary / Completion435.4.Central Visibility / Inspection Control445.4.1.Inspection Control Board445.4.2.Statutory Compliance455.5.Notification Workflow475.5.1.Notification Control Board475.5.2.Modify Notification475.5.3.Communication495.5.4.Create a Workorder from a Notification506.Learning Summary52

OverviewAMT OverviewAMT is a comprehensive asset management system consists of integrated modules as depicted below.Functionality covered in this training manual part of Short Term Planning, Condition Based Maintenance and AMT Mobile.

For more information on the modules see the AMT Functionality presentation.

Overview of CMAMT has a comprehensive Condition Monitoring (CM) suite, comprised of several different solutions. Advantages of CM in AMT include: Flexibility Condition monitoring data and alerts from any sources Efficiency Central dashboard to streamline actions ERP bolt on Easily integrated with other ERP systems Mobility Mobile apps for Inspections, Measurements, Usages, Defects, Statutory Compliance Simple Easy to configure, setup rule sets and implement Statutory Compliance Monitor your statutory inspections regime Live RCM Option to incorporate advanced RCM rule sets when required (ADVANCED OPTION)There are 4 main solutions supported each is summarised below.

A. Measurements

B. Inspections

C. Direct Capture of Notifications

D. Live RCM (also known as Condition Based Maintenance or CBM)

Putting it all Together: A Comprehensive CM Suite

Login and NavigationFor information on AMT login and navigation, refer to the handbook H - Getting Around AMT.docx.TerminologyFor information on AMT terminology, refer to the handbook H - AMT Terminology.docx.

Learning ObjectivesAt the completion of this course, participants should understand and be able to perform the following. Concepts Basic understanding of RCM, CM, CBM and RA (Reliability Analysis) High level understanding of how the AMT modules/functionality fit together Setup Measurements Setup CM Codes for Measurements in the system table Measurement translation rules Setting up measurement translation rules Difference between standard method and Use External rating Actions Actual Measurements Entering manually Importing Entering on a WO Entering on a checksheet (Mobile) Understand the rating of a measurement Knowledge Database Electronic Workscope Manager Setup Inspection Templates Awareness of Inspection Config Understand Inspection Types Understand Inspection Display Modes Understand Labour Activity and filtering of Inspections Statutory Compliance View and understand Statutory Compliance (AMT Web) View and understand Statutory Compliance (AMT Mobile) Perform Inspections View / Record Usages in AMT Mobile View / Record Measurements in AMT Mobile View / Record Defects in AMT Mobile Perform Inspection Steps Understand the 4 different Inspection display modes (and config) Understand Operational Impact Perform Inspection Step linked to CM Code Inspection Control Board View completed Inspections Create Notification from Inspection Notification Control Board View, sort, filter Notifications to find items that require action Communication workflow of a Notification Create Workorder from Notification

ProcessesA: Measurements ProcessObjectivesThe objectives of the inspections process are: Configure CM Codes Configure Measurement Translation rules Capture Measurement Readings (AMT Mobile)and/or Capture Measurement Readings (AMT Windows Client)and/or Import Measurement Readings from external systemsProcess OwnerStrategist / Reliability EngineerOutputsThe outputs (deliverables) are: Measurement Readings and Measurement Ratings Notifications created from Measurement TranslationInputsInputs to the inspection process are: Knowledge of organizations Condition Monitoring requirements

Process Diagram

B: Inspections ProcessObjectivesThe objectives of the inspections process are: Perform inspections on assets Record inspection step results, including rating levels Record CM measurements as part of inspection steps Monitor and ensure statutory compliance of regulatory inspectionsProcess OwnerStrategist / Reliability EngineerOutputsThe outputs (deliverables) are: Inspection results and feedback information Notification of Inspection Step ratings CM Measurements recorded as part of Inspection StepsInputsInputs to the inspection process are: Inspection Strategy (Strategy Definition) Inspection Templates (Knowledge Database)

Process Diagram

C: Direct Notification Process Objectives The objectives of the inspections process are: View/Record Notifications in AMT Import Notifications from an external systemProcess OwnerStrategist / Reliability EngineerOutputsThe outputs (deliverables) are: NotificationsInputsInputs to the inspection process are: Knowledge of organizations Condition Monitoring requirements

Process Diagram

D: Live RCM ProcessRCM is short for Reliability Centred Maintenance; it is process of interpreting Condition Monitoring data against reliability assumptions to optimise maintenance decisions. It is more complex than the Condition Monitoring features covered in this training manual, and should be used for high value components where the cost of failure is significant and justifies the additional complexity.The diagram below illustrates the components of Live RCM at a high level.

Live RCM is not covered in this training manual.For more details on Condition Based Maintenance, please see P Condition Based Maintenance.docx

Procedures (A: Measurements)Configure Measurement CodesWhen actual measurements are received by AMT, they are classified into four ratings based on user-defined translation rules. User can set AMT to auto create a notification and/or workorder if the measurement reading reaches a certain rating.Before setting up Measurement Translation Rules, the corresponded measurement code has to be set up in AMT.In AMT Client, open System Administration Usages & Measurements Measurement Code.

In Measurement Code, a list of existing measurements codes is displayed.

To add a new measurement code, press the blue + button.To edit an existing measurement code, select the code from the list, then click the blue E button.To delete a measurement code, select the code from the list, then click the orange X button.System ParameterDescriptionExample

Element CodeMeasurement CodePB for lead level in Engine oil

Element DescriptionDescription of the Element Codelead level in Engine oil

Element UOMUnit of measure for that elementppm, mm, Celsius, Integer etc.

Lower Normal LevelThe normal lower limit for that measurement0

Upper Normal LevelThe normal upper limit for that measurement100

Measurement Type CodeWhat sort of measurement it isEO, TTD

Measurement Type DescriptionWhat sort of measurement it isEngine oil, Tyre Tread Depth

CompartmentWhere the measurement is takenEngine, Final Drive, Front left tyre, etc.

CategoryWhat type of measurement it isInspection, Level, Telemetry, etc.

Component CodeIndicate which component the measurement was taken from4000 for engine

Workorder MeasurementTo be viewable and editable in workorderCheckbox

Configure Measurement Translation RulesOnce the measurement code has been setup, a translation rule needs to be defined for that measurement code. Translation rules have 2 main purposes.1. To prevent invalid measurements from being accepted by AMT.2. To establish ratings as to which level/range of measurement is and which will generate a notification and/or workorder.In AMT Client, open knowledge Database Condition Based Maintenance Measurement Translation Rule.

Add a new CM Translation Rule by click the blue + button.The only compulsory code in code in this table is CM Code; this is used for the name of the CM translation rule. This field reads from the list of measurement code. E.g. Tread Depth (TD) Tyre Tread depth, Silicon (SI) Engine oil, etc. A CM Translation rule cannot be created if the CM code doesnt exist in measurement code.Model, Equipment Group, Equipment Class, Fleet, Site, Component Code, Primary Part Number, Part Rating and Manufacturer not compulsory fields they are used as filters. If these fields are all left blank, then the CM Translation rule will apply for all assets. If the CM Translation rule is only for a certain group of assets, it can be defined by populating the corresponding fields. For example if one wants to create a CM Translation rule only for the engine oil copper level for all off-high way mining trucks in Site XYZ, He needs to set CM Code* as Copper (CU) Engine Oil, Equipment Class as OHT and Site as XYZ Once a CM Translation Rule has been created, each translation rule has to have 4 translation levels. User can add a translation Level by clicking. In AMT, every CM Translation Rule must have 4 translation levels. The Condition of each level cannot have range overlap with each other. If External rating is used, make sure Use Ext Rating checkbox is ticked. If user wants certain rating levels to generate a Notification and/or Workorder, please make sure Create Notification and/or Create Workorder check box is checked.

The rule applied to the measurement entered to create the chosen alertThe AMT OK rating when the condition is met If the external system sends a rating, tick this box.

Notes Ratings from external systems are text based categories assigned to sample results, e.g. F or FAIL Readings from external systems are numeric measurements such as 200ppm Ratings from external systems imported into AMT are assigned an AMT Alert reading (3 Medium Alert) based on the condition entered, e.g. = F, when the Use Ext. Rating is tickedView / Record Measurements (AMT Client)Navigate to Daily Operations / Usages & Measurements / Record Actual Measurement Readings. Setting the appropriate filters Setting Display Records with No Readings = Yes (If the measurement is newly added and has no previous readings) To add a new measurement, click the + button, then a new role column Measurement will appear, type in the new reading. Comments can be added in Other Comments filed. If a measurement reading is out of range or doesnt meet the CM Translation Rule, then the reading be display in Grey colour and marked as Ignored.

It is possible to paste values from a spreadsheet program into AMT rather than entering the values one by one. Simply right-click on the Grid, select Copy Table, paste it into the spreadsheet program, complete the empty cells, and then Paste back into AMT

Condition Monitoring Training ManualPage 22

After the reading has been entered, the user should click the Refresh button to see how the measurement was classified.

ColourDescription

OK

Low Level Alert

Medium Alert

High Alert

Invalid Reading

View / Record Measurements (AMT Mobile)Measurements can also be recorded in AMT Mobile.Navigate to Inspection Select a site Measurements

To filter measurements, click Refine

Measurements can be filtered by asset, fleet and measurement.To add a new measurement, click on Record Measurement.To add a measurement reading comment, click on the measurement.

Import Measurements from External SystemsMeasurement Readings can also be imported from external source, once the measurement translation rule has been established as Use external rating. It can read any measurement readings, the readings are imported using an .xml or .csv file through the interface folder. For more details, please see: AMT System Integration Measurement.docxExercise 1 Configure and Record MeasurementsOpen Measurement Codes from My Functions and create a new Measurement CodeOpen Measurement Translation Rule from My Functions and create 1 translation and 4 translation levels rule for this new code, set level 3 to auto create notification and level 4 to auto create workorderRecord various measurements ranging from Level 1 to 4 from both AMT Client and AMT Mobile.Validate the measurement readings

Procedures (B: Inspections)Setup Inspection TemplatesElectronic Workscope ManagerElectronic Workscope Manager is used to define Inspection Templates. To access Electronic Workscope Manager, navigate to Knowledge Database / Electronic Workscope Manager.

Inspection ConfigInspection Config determines the nodes that appear in the inspection and the configuration of each node in that Inspection.IMPORTANT: There is no editor for Inspection configurations; the configurations can be loaded into the AMT database by iSolutions. Inspection configurations can be reviewed and modified in a workshop with iSolutions when AMT Mobile is deployed. Changes or new configurations can only be performed by iSolutions. Please contact your iSolutions rep for more informationInspection Config defines the nodes that make up an Inspection; basically this is the workflow the user must follow to complete the Inspection. The possible nodes are listed below.

Usages: Users can view and/or record Usage ReadingsMeasurements: Users can view and/or record Measurements; Measurements are interpreted (colour coded ratings) in real-timeDefects: Users can view and/or record DefectsInspection Steps: These are the steps defined in the Electronic WorkscopeInspection StepsEach Inspection is made up of a series of Inspection Steps. These are defined in the grid on the bottom half of the Electronic Workscope Manager screen.

Each Inspection Step field is explained in the table below.System ParameterDescriptionExample

SequenceThe order of when each inspection tasks1,2,3,4etc.

Component CodeComponent code for the item being inspected1000 for engine, 4000 for brakes, etc.

TitleThe name of the inspection tasksCheck engine oil level

CM CodeReading /Measurement of each inspection taskTemperature, wear measurements, etc.

InstructionsInspection task procedureTake the lowest of 4 measurements

SafetyWhether or not if this inspection task is Safety relatedtick box

EnvironmentalWhether or not if this inspection task is Environmental relatedtick box

Document File NameThe name of the SWI for this inspection taskfilename

Operation ImpactThe severity of the impact if this asset fail this inspection taskUnsafe

Inspection TypeInspection Type helps users (e.g. Operators, Supervisors, Mechanics, and Inspectors) find relevant Inspections. An Inspection Type is linked to a Labour Activity this is how the list of Inspections that an Employee can select from in the AMT Mobile Inspections module is filtered.Inspection Item Node During an inspection, inspector can also view/edit defects, record usages and measurements. There are four Inspection Item Nodes in AMT. Record Usages View/edit Defects Perform Inspection Record Measurement Inspection SummaryRecord Usages

View/edit Defects

Perform Inspection

Record Measurements

Inspection Summary

According to customers requirement, Inspection item node can be setup to display in any order and repeat multiple times. Example 1: View Defects Record Measurements Record Usages Perform Inspections Example 2: Record Usages Perform Inspections Record Measurement Record Usages View DefectsIMPORTANT: There is no editor for Inspection Item Node configurations; the configurations can be loaded into the AMT database by iSolutions. Inspection Item Node configuration can be reviewed and modified in a workshop with iSolutions when AMT Mobile is deployed. Changes or new configurations can only be performed by iSolutions. Please contact your iSolutions rep for more information.Inspection Display ModesDepending on who is performing an Inspection, different types of Inspection require different levels of detail in the AMT Mobile UI. This is achieved by four different display modes (each Inspection Config is linked to an Inspection Display Mode):1. Simple Wizard2. Simple Checklist3. Advanced Wizard4. Advanced ChecklistFor example, Operators may only need to use a Simple Checklist, so they can quickly perform a pre-start Inspection on an Asset. However, mechanics performing a detailed preventive maintenance Inspection might want to note down some details and comments of each inspection task, or add photos and videos as attachments.Display ModesFeature

SimpleFor each inspection step, inspector can mark it as OK or Defect

AdvancedFor each inspection step, inspector can give a rating from 1 to 4

WizardEach inspection step is one page, easy to add inspection details for each step

ListAll inspection steps display in one page, check - list style

The screenshot below shows a Simple Checklist:

And this shows one Inspection Step within an Advanced Wizard:

Statutory ComplianceUsers can see the status of Strategy Tasks (e.g. Inspections) that must be audited (e.g. for regulatory reasons) in the Statutory Compliance screen.For each Strategy Task, Statutory Compliance shows: (i) when it was last performed, (ii) the last Workorder Number, and (iii) the Next Due Date.

Condition Monitoring Training ManualPage 25

Colour coding is used to highlight the status:Not yet within 10% of frequency

Within 10% of frequency

Past compliance

The Statutory Compliance screen can be accessed in AMT Mobile at Inspections / Statutory Compliance.

Perform an InspectionSelect SiteA Site must be selected.

Once a Site has been selected, navigate to Inspections from the menu.

Employee LoginThe Employee performing the Inspection must login. Employee accounts are protected by an Employee PIN. Only an Administrator can change an Employees PIN.

Select AssetSelect an Asset to inspect.

Select an InspectionSelect an Inspection.

The list of Inspections: Is filtered by Inspection Type Is restricted to Inspections allowed for the Labour Activity of the Employee performing the Inspection Includes incomplete Inspections (these show in the list with the previous date/time in brackets after the Inspection Name), so Employees can resume and complete these Inspections (e.g. A mobile may have lost power while an Inspection was in progress)Select Start Date / TimeThe Asset, Employee and the selected Inspection are displayed. The Start Date / Time can be modified and confirmed before commencing the Inspection.

View / Record UsagesThe most recent usage values are shown.

After pressing the Record Usages button, new usage readings can be entered. These are subject to the same validation rules as any usage readings entered into AMT.

View / Record DefectsIn Defects, all current defects listed on the selected site will be displayed. User can filter defects by Asset and Fleet by clicking the Refine button.To add a new defect, click the red Add new Defect button.

In Add New Defect page, user can enter the details of the defect, user Repair Instructions and attachment photos or documents can also be added.

Perform Inspection StepsThe screenshot below shows an example of an Inspection configured to display as a simple checklist. Each step can be flagged as either Ok or Defect and Feedback information can be entered.

Feedback can be entered by pressing the Feedback button.

Instructions for the Inspection Step can be viewed by pressing the Instructions button. The Instructions indicate if the Inspection Step has Safety or Environmental implications, and optionally include an image to graphically explain the Step Instructions.

Inspection Summary / CompletionOnce all Inspection Steps have been performed, an Inspection Summary screen is shown.Pressing the View Defects Raised button will show the user the Inspection Steps that were flagged as Defect.Once the Save & Close button is pressed, the Inspection is completed.

Exercise 2 Create a new Inspection TemplateOpen Electronic Workscope Manager from My Functions and create a new Inspection for one equipment modelSetup 7 inspection steps for this new inspection you just createdLaunch AMT Mobile and try to perform an Inspection using the inspection template you just created.

Central Visibility / Inspection ControlInspection Control BoardThe Inspection Control Board allows users to view, manage and edit Inspections. It can be launched by navigating to Daily Operations / Inspections.The left hand side of the split screen shows a list of Inspections in a grid. Full grid filtering and sorting features are available.The right hand side of the split screen shows details of the Inspection selected in the grid.To create a Notification from an Inspection, press the Add Notification button.If a Notification has been created for this Inspection, then the Notification Created check box will be checked and the black button on the right hand side will change to Go to Notification.

Statutory ComplianceUsers can see the status of Strategy Tasks (e.g. Inspections) that must be audited (e.g. for regulatory reasons) in the Statutory Compliance screen.Statutory Compliance is available by navigating to Daily Planning / Statutory Compliance.For each Strategy Task, Statutory Compliance shows: (i) when it was last performed, (ii) the last Workorder Number, and (iii) the Next Due Date.Colour coding is used to highlight the status:Not yet within 10% of frequency

Within 10% of frequency

Past compliance

How to Configure a Strategy Task to Show in Statutory ComplianceIn order to have the strategy tasks viewable in Statutory Compliance, it has to meet two criteria.

1: The strategy task must be a Planning Task:

2: In the Job Details of the Strategy Task, OH&S must be set to a value that is flagged as auditable in the OH&S system table:

Exercise 3 Set a task as statutory taskSelect an equipment, and choose set one of its strategy tasks as statutory taskOpen Statutory Compliance from My Functions and filter for that equipmentSee if that statutory task show up in Statutory Compliance

Notification WorkflowNotification Control BoardThe Notification Control Board allows users to view, manage and edit Notifications. It can be launched by navigating to Daily Operations / Notifications.The left hand side of the split screen shows a list of Notifications in a grid. Full grid filtering and sorting features are available.The right hand side of the split screen shows details of the Notification selected in the grid.

Modify NotificationUsers can modify the details of each notification: Rating of the Notification (1 OK; 2 Low Alert; 3 Medium Alert; 4 High Alert) Assigned To (Account Manager; Coordinator; Customer; Service) Assigned To Person (Type in the name) Status (Acknowledged; Assigned; Closed; Customer Contacted; Open) Workorder (If there is one, the Workorder Number will display here) Comments (add a comment and view others comments) Communicate (Manually send an email to notify someone and view previous emails)To view or print the Notification Details, click on the Actions button.

In the Raise tab, details of the Notification can be viewed. Repair Instructions can be added and photos/documents can be attached.

CommunicationIn the Assign and Action tab, Workorder Details can be viewed (e.g. Workorder Number, Title, Date Created, and Workorder Status).

In the Audit tab, an audit trail is displayed with the most recent record at the top.

Create a Workorder from a NotificationA Workorder could have been automatically generated by an Inspection, Measurement or CBM rules.A user can also manually create a Workorder from a Notification.

To create a Workorder from a Notification, in the right pane click on Actions and choose Create Workorder.

Once the Workorder has been saved, in Assign and Action of that Notification the Workorder Number and Title is displayed the Auto Created check box is unchecked in this case.

Exercise 4 Manage NotificationOpen Notifications from My Functions.Try to filter, sort some notificationsSelect a notification and manually created a workorder for that notificationSelect a notification and manually send an email to your colleague or yourself

Learning Summary(Recap of learning objectives) Concepts Basic understanding of RCM, CM, CBM and RA (Reliability Analysis) High level understanding of how the AMT modules/functionality fit together Knowledge Database Electronic Workscope Manager Setup Inspection Templates Awareness of Inspection Config Understand Inspection Types Understand Inspection Display Modes Understand Labour Activity and filtering of Inspections Statutory Compliance View and understand Statutory Compliance (AMT Web) View and understand Statutory Compliance (AMT Mobile) Perform Inspections View / Record Usages in AMT Mobile View / Record Measurements in AMT Mobile View / Record Defects in AMT Mobile Perform Inspection Steps Understand the 4 different Inspection display modes (and config) Understand Operational Impact Perform Inspection Step linked to CM Code Setup Measurements Setup CM Codes for Measurements in the system table Measurement translation rules Setting up measurement translation rules Difference between standard method and Use External rating Actions Actual Measurements Entering manually Importing Entering on a WO Entering on a checksheet (Mobile) Understand the rating of a measurement Inspection Control Board View completed Inspections Create Notification from Inspection Notification Control Board View, sort, filter Notifications to find items that require action Communication workflow of a Notification Create Workorder from Notification