Int’Graal – Integrated Maintenance Operations Management
Module that supports the asset management of a system during its life cycle, from the preliminary design phase to the end of operation, supporting the RAMS methodology. It enables the plant and equipment modelling using hierarchical structures of granular elements, with attributes to describe the technical characteristics, the failure modes & quantification, the predetermined or fortuitous maintenance operations and the condition or process parameters that constrain them.
Maintenance plans can be calculated analytically based on statistical distributions of failure, repair, replacement, etc., considering its operational context and its objectives of life cycle cost, availability and reliability.
Int’Graal supports an analytical and predictive approach to maintenance via an adaptive planning built on maintenance plans and the predicted evolution of defined condition parameters.
This approach makes possible to define the most effective task scheduling, based on information from various sources, namely: The failures, works and material consumption history; the Production plan and the evolution of the parameters and counters values which constrain the maintenance plans tasks.
Individual Solution characterization
Characterization of installations
Plant and system presentation via lay-out or process diagram. Each functional unit is identified by tag numbers and characterized by functional characteristics, and contextual constraints (e.g., rate of use, time allocation).
Registration of equipment
Equipment is identified by a code in which its morphology is represented according to a granular perspective, or functional tree, forming entities. Entities are coded down to the level of the item subject to LRU (Line Replaceable Unit) replacement or SRU (Shop Replaceable Unit) repair.
Faults, production irregularities, Functional Analysis and Fmeca
Functional analysis support and Fmeca analysis are supported. Definition of faults created on the functional structure of the element, and their propagation upwards or to a branch at the same level. Supports the reporting of faults, their analysis and the monitoring of actions to overcome them, i.e. configures FRACAS – Failure Reporting, Analysis, and Corrective Action System capability.
Failure models and converting data into statistical distributions
Representation of failure models via probabilistic distributions based on historical data on failures, repairs, etc. These models are used to define maintenance plans and to support immediate or, if possible, planned corrective interventions.
Severity, criticality and maintenance strategies
Definition of the maintenance model to be applied to each functional unit identified by a Tag code. This can be defined using several parameters, for instance, criticality (severity and probability of occurrence), costing, Resource required specialization, equipment redundancy, condition monitoring, etc.
Parameter and counter data
Information support for counters and parameters associated to equipment points and their locations. These can be scalar or complex quantities (vibrations) provided by signal acquisition systems, Scada systems, technical management systems or vibration analysis collectors (e.g. global value, frequency band, frequency of interest).
Stocks, material movements and warehouses
Stock and warehouse management support, incoming and outgoing movements and procurement processes, via enquiries/orders or purchase orders. Support for reservations and consignments of materials for construction work.
Management of workshops and human resources
Management of the resources involved in operations. Operations are carried out using the resources available in the workshops or work centres that support the activity.
Maintenance Ontology
Definition of the ontology applicable to the world of maintenance. Defining an operation as one or a set of tasks performed on one or a set of maintenance items or objects, by one or more trade specialties (electrical, mechanical, instrumentation), integrated into a work center(s) or workshop.
Managing all operations
Maintenance Plans (Preventive, inspection and lubrication)
Maintenance plans carry out periodic replacements, based on time or counters, and conduct inspections to assess the condition of equipment, guaranteeing reliability. These pre-determined operations intervene before the expected useful life of the components is exceeded. The strategy uses analytical calculations, based on failure and repair models, and allows optimisations to define the ideal periodicity.
Planning and scheduling
Planning organises tasks with defined dates or sequences, integrating plans, meter dependencies, inspections or work orders. It adapts to finite resources of materials and labour, rescheduling delayed tasks when necessary and allowing manual adjustments to align with operating conditions.
Work order management
Centralised management and reporting of planned and incidental operations, organising the scheduling of activities and distributing the load to the operational team via work orders (WOs). It offers configurable flows to define the modus operandi and processing of information based on criteria such as urgency and criticality.
Life cycle costing Reliability and Availability
Life cycle cost forecasting and evolution of availability and reliability of functional units or higher locations, calculating plans analytically. Allows maintenance strategies to be validated effectively.
Dynamic planning
Adjustment of operation dates generated by plans calculated analytically and conditioned by the evolution of condition parameters. Combines statistical information that allows performance to be predicted based on a failure model with real-time information on the condition, validating and correcting the prediction.
Work requests and event management
Support for an event management system, by configurable types, including different contexts such as quality management and energy safety. Ticketing system to complement the functionalities described and complete the list of tasks assigned to each employee.
Geographical navigation
Layout representation of functional units and equipment, with zoom and sequenced screens features, completely configurable.
Configurable metrics and indicators
A wide range of configurable indicators and metrics to characterize the performance of plants, production lines and equipment, in several views.
Reports and information on operations and equipment
Management control tools that make it possible to visualise progress in terms of costs, faults, intervention, etc. Configuration of reports produced semi-automatically to describe the performance obtained or the indicators calculated for a defined period.
Life cycle costing – reliability and availability
Forecasting the life cycle cost and evolution of the availability and reliability of functional units or higher-level locations, provided that the plans have been calculated analytically. This functionality allows maintenance strategies to be validated.
Import from various sources
Compatibility of importing data in various formats and from various sources, to complete the necessary information, such as process data from technical information systems, SCADAS, or data on faults reported or materials consumed reported in ERPs or CMMSs.
Document Management
It supports information on interventions, manuals, fault characterisation and maintenance operations, and can support and issue technical reports or technical information such as specifications.
Predictive maintenance analysis based on real-world data
Features
Statistical functions – Reliability or maintainability
Maintenance, inspection and shutdown operations are calculated analytically, based on the knowledge and experience of more than 30 years of industrial, commercial and service activity.