Monitoring

Purpose

Monitoring is a specialised field of Maintenance Engineering that results in the proactive maintenance of Assets if applied properly.

Record and track the operating conditions and “wear and tear” of an Asset over time, so that early action can be taken to pre-empt failure or loss of production due to a breakdown.

Use the Maintenance Manager module to:

• Configure the Monitoring Point Types and Monitoring Points for the Assets on which Monitoring Point Readings are required. Refer to Master Data for ACPD Monitoring for information.
• Record Monitoring Point Readings for each Monitoring Point on an Asset.
• Configure Alarm Types.
• Generate Alarms when recorded Monitoring Point Readings are out of range for a Monitoring Point on an Asset.
• Generate Work Orders for the maintenance of an Asset based on the Alarm condition (from the Alarm edit window in the Maintenance Manager, Monitoring module).

Key points

• Monitoring only applies to Assets for which Maintain this Asset (MSI) is ticked.
• Monitoring only applies to inspection Tasks for an Asset (Inspection is ticked on the Asset Task edit window) that are:
• • not Pass/Fail type Tasks
  • linked to Monitoring Points (Reading Required is ticked on the Asset Task - Details tab).
• Inspection Tasks may have Follow Up Tasks that are triggered if a Reading for a Monitoring Point exceeds the specified bounds. The Follow Up Tasks do not have to be Inspection Tasks.

Implementation Guidelines

Carefully evaluate which Assets and what operating conditions are to be monitored before using the features provided by this module.

To ensure that monitoring efforts are cost effective, only implement monitoring for complete assembly lines or instruments on critical Assets.

Monitoring Assets, Readings and Alarms

An Asset can have a Monitoring Point on one or more Components, which are used to monitor the Asset.

The reading values at which an Alarm is raised, and the type of Alarm that is raised, are specified for each Monitoring Point (and the Monitoring Point Type that it is associated with).

Readings or measurements for an Asset’s Monitoring Points can be:

• Taken manually and recorded as Monitoring Point Readings, or
• Generated automatically if the Performance Management system is used and the Monitoring Point is linked to an OPC Tag.

An Alarm is raised when a Reading is out of the bounds for the specified Monitoring Point. The Alarm Description is generated by the system using the associated Alarm Type and the circumstances that led to it being raised.
For example, “Monitoring point:*1009 has exceeded upper bound 2 by 213 RPM. Alarm Type : [CML2] Condition Monitor”.

The Planner uses the Maintenance Manager - Monitoring - Alarms menu option to:

• View Alarms that have been raised, and
• • Generate a Work Order to respond to the Alarm (from the Alarm edit window).
  • The Work Order’s Work Required defaults to the Alarm Description that was generated when the Alarm was raised.
  • The Work Order Task that is associated with the Alarm describes the action to be taken.

The Operator or Artisan who is assigned to do the work,

• Takes readings at the specified Monitoring Points, and
• Records the readings on a Recordings Sheet or printed Work Order.

The Maintenance Engineer or Planner uses the system to:

• Add Monitoring Point Readings in the system from the Recordings Sheet.
• View Alarms that have been generated for Monitoring Point Readings that are out of bounds.
• Generate Work Orders from Alarms to maintain the Assets.

Generating Work Orders to monitor Assets

A Work Order to inspect and maintain an Asset can be generated in the following ways.

• Click  on the Alarm edit window after an Alarm is raised. The system:
• • Identifies Inspection Tasks that are linked to the Monitoring Point on the Asset for which the Alarm was raised.
  • Identifies the Follow Up Tasks that are linked to the Alarm Type specified for the Monitoring Point Reading that is out of bounds, and includes them as Tasks in the new Work Order. These Tasks apply to the same Monitoring Point as the original Work Order’s Inspection Task if the Alarm was raised as a result of Feedback on a Work Order.
• Add a Work Order for an Asset that requires monitoring.

© 2016 Pragma