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Condition Monitoring
Page 2
Training Manual
Condition Monitoring
Prepared By:
Approved By:
Date:
Feb 2015
Table of Contents
1.
Overview............................................................................................................................... 5
1.1.
AMT Overview................................................................................................................ 5
1.2.
Overview of CM.............................................................................................................. 6
Page 3
1.3.
1.4.
Terminology................................................................................................................... 9
2.
Learning Objectives............................................................................................................. 10
3.
Processes............................................................................................................................ 12
3.1.
A: Measurements Process............................................................................................12
3.1.1. Objectives................................................................................................................ 12
3.1.2. Process Owner.......................................................................................................... 12
3.1.3. Outputs.................................................................................................................... 12
3.1.4. Inputs....................................................................................................................... 12
3.1.5. Process Diagram....................................................................................................... 13
3.2.
B: Inspections Process.................................................................................................14
3.2.1. Objectives................................................................................................................ 14
3.2.2. Process Owner.......................................................................................................... 14
3.2.3. Outputs.................................................................................................................... 14
3.2.4. Inputs....................................................................................................................... 14
3.2.5. Process Diagram....................................................................................................... 15
3.3.
3.3.1. Objectives................................................................................................................ 16
3.3.2. Process Owner.......................................................................................................... 16
3.3.3. Outputs.................................................................................................................... 16
3.3.4. Inputs....................................................................................................................... 16
3.3.5. Process Diagram....................................................................................................... 17
3.4.
4.
5.
Page 4
Statutory Compliance..................................................................................................34
5.3.
Perform an Inspection.................................................................................................. 35
Notification Workflow................................................................................................... 47
Learning Summary.............................................................................................................. 52
Page 5
Overview
1.1.
AMT Overview
For more information on the modules see the AMT Functionality presentation.
Page 6
1.2.
Overview of CM
AMT has a comprehensive Condition Monitoring (CM) suite, comprised of several different
solutions. Advantages of CM in AMT include:
A. Measurements
B. Inspections
Page 7
Page 8
Page 9
1.3.
For information on AMT login and navigation, refer to the handbook H - Getting Around
AMT.docx.
1.4.
Terminology
Page 10
2. Learning Objectives
At the completion of this course, participants should understand and be able to perform the
following.
Concepts
o Basic understanding of RCM, CM, CBM and RA (Reliability Analysis)
o High level understanding of how the AMT modules/functionality fit together
Setup Measurements
o Setup CM Codes for Measurements in the system table
Measurement translation rules
o Setting up measurement translation rules
o Difference between standard method and Use External rating
o Actions
Actual Measurements
o Entering manually
o Importing
o Entering on a WO
o Entering on a checksheet (Mobile)
Understand the rating of a measurement Knowledge Database
o Electronic Workscope Manager
o Setup Inspection Templates
o Awareness of Inspection Config
o Understand Inspection Types
o Understand Inspection Display Modes
o Understand Labour Activity and filtering of Inspections
Statutory Compliance
o View and understand Statutory Compliance (AMT Web)
o View and understand Statutory Compliance (AMT Mobile)
Perform Inspections
o View / Record Usages in AMT Mobile
o View / Record Measurements in AMT Mobile
o View / Record Defects in AMT Mobile
o Perform Inspection Steps
o Understand the 4 different Inspection display modes (and config)
o Understand Operational Impact
o Perform Inspection Step linked to CM Code
Inspection Control Board
o View completed Inspections
o Create Notification from Inspection
Notification Control Board
o View, sort, filter Notifications to find items that require action
o Communication workflow of a Notification
o Create Workorder from Notification
Page 11
3. Processes
3.1.
1.1.1.
A: Measurements Process
Objectives
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 systems
1.1.2.
Process Owner
1.1.3.
Outputs
1.1.4.
Inputs
Page 12
1.1.5.
Process Diagram
Page 13
Page 14
Notification
Workfow
Measurement
Translation
Record / Import
Measurements
Knowledge
Database
Create Workorder
Yes
Corrective
WO
Required?
Notification
Control Board
No
Communication
SetupMeasurement
Translation Rules
Configure
MeasurementCodes
Measurement
Translation
System
View / Record
Notifications
Inspector/Mechanic
View / Record
Measurements
Select Site
Import
Measurements
External System
3.2.
1.1.6.
B: Inspections Process
Objectives
1.1.7.
Process Owner
1.1.8.
Outputs
1.1.9.
Inputs
Page 15
Notification
Workfow
Central Visibility /
Inspection Control
PerformInspection
Statutory Compliance
Knowledge Database
Strategy Definition
Create Workorder
Yes
Corrective
WO
Required?
Notification
Control Board
No
Communicatio
n
SetupInspection
Templates
Define
Inspection
Strategy
Statutory
Compliance
Create Notification
Inspection Control
Board
Statutory
Compliance
Planner
Employee Login
Perform
Inspection Steps
Select Site
View / Record
Usages
View / Record
Defects
Statutory
Compliance
(AMT Mobile)
Inspection
Summary/
Completion
Select Inspection
Select Asset
Perform
InspectionSteps
Inspection
Summary/
Completion
Employee Login
Select Site
Select Inspection
Select Asset
1.1.10.
Process Diagram
Page 16
3.3.
1.1.11.
Objectives
1.1.12.
Process Owner
1.1.13.
Outputs
Notifications
1.1.14.
Inputs
Page 17
1.1.15.
Process Diagram
Page 18
3.4.
Page 19
When 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.
Description
Measurement Code
Element Description
Element UOM
Example
PB for lead level in Engine
oil
lead level in Engine oil
ppm, mm, Celsius, Integer
Page 20
Type
Category
Component Code
Workorder Measurement
1.1.17.
element
The normal lower limit for
that measurement
The normal upper limit for
that measurement
What sort of measurement it
is
What sort of measurement it
is
Where the measurement is
taken
What type of measurement it
is
Indicate which component the
measurement was taken from
To be viewable and editable in
workorder
etc.
0
100
EO, TTD
Engine oil, Tyre Tread Depth
Engine, Final Drive, Front left
tyre, etc.
Inspection, Level, Telemetry,
etc.
4000 for engine
Checkbox
Once 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.
Page 21
Once a CM Translation Rule has been created, each translation rule has to have 4
translation levels.
Page 22
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
ticked
1.1.18.
Navigate to Daily Operations / Usages & Measurements / Record Actual Measurement Readings.
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.
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.
Page 23
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
Page 24
Colour
Description
OK
Low Level Alert
Medium Alert
High Alert
Invalid Reading
Page 25
Page 26
1.1.19.
Page 27
Page 28
1.1.20.
Measurement 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.docx
Record various measurements ranging from Level 1 to 4 from both AMT Client and
AMT Mobile.
Page 29
1.1.22.
Inspection Config
Inspection 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 information
Inspection 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.
Page 30
1.1.23.
Inspection Steps
Each 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.
1,2,3,4etc.
Component Code
Title
CM Code
Instructions
Safety
Environmental
Document
File
Name
Operation Impact
Description
Example
Temperature,
measurements, etc.
Take
the
lowest
measurements
tick box
for
wear
of
tick box
filename
Unsafe
Page 31
1.1.24.
Inspection Type
Inspection 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.
1.1.25.
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 Summary
Record Usages
View/edit Defects
Page 32
Perform Inspection
Record Measurements
Page 33
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
Condition Monitoring Training Manual
Page 34
1.1.26.
Simple Wizard
Simple Checklist
Advanced Wizard
Advanced Checklist
For 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
Modes
Simple
Advanced
Wizard
List
Feature
For each inspection step, inspector can mark it as OK or Defect
For each inspection step, inspector can give a rating from 1 to 4
Each inspection step is one page, easy to add inspection details for each
step
All inspection steps display in one page, check - list style
Page 35
1.1.27.
Page 36
5.2.
Statutory Compliance
Users 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.
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.
Page 37
5.3.
1.1.28.
Perform an Inspection
Select Site
Once a Site has been selected, navigate to Inspections from the menu.
1.1.29.
Employee Login
The Employee performing the Inspection must login. Employee accounts are protected by an
Employee PIN. Only an Administrator can change an Employees PIN.
1.1.30.
Select Asset
1.1.31.
Select an Inspection
Select an Inspection.
1.1.32.
The Asset, Employee and the selected Inspection are displayed. The Start Date / Time can be
modified and confirmed before commencing the Inspection.
1.1.33.
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.
1.1.34.
In 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.
1.1.35.
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.
1.1.36.
Once 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.
Setup 7 inspection steps for this new inspection you just created
Launch AMT Mobile and try to perform an Inspection using the inspection template
you just created.
5.4.
1.1.37.
The 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.
1.1.38.
Statutory Compliance
Users 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:
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:
Select an equipment, and choose set one of its strategy tasks as statutory task
Open Statutory Compliance from My Functions and filter for that equipment
5.5.
1.1.39.
Notification Workfow
Notification Control Board
The 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.
1.1.40.
Modify 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)
In the Raise tab, details of the Notification can be viewed. Repair Instructions can be added
and photos/documents can be attached.
1.1.41.
Communication
In 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.
1.1.42.
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.
6. Learning Summary
(Recap of learning objectives)
Concepts
o Basic understanding of RCM, CM, CBM and RA (Reliability Analysis)
o High level understanding of how the AMT modules/functionality fit together
Knowledge Database
o Electronic Workscope Manager
o Setup Inspection Templates
o Awareness of Inspection Config
o Understand Inspection Types
o Understand Inspection Display Modes
o Understand Labour Activity and filtering of Inspections
Statutory Compliance
o View and understand Statutory Compliance (AMT Web)
o View and understand Statutory Compliance (AMT Mobile)
Perform Inspections
o View / Record Usages in AMT Mobile
o View / Record Measurements in AMT Mobile
o View / Record Defects in AMT Mobile
o Perform Inspection Steps
o Understand the 4 different Inspection display modes (and config)
o Understand Operational Impact
o Perform Inspection Step linked to CM Code
Setup Measurements
o Setup CM Codes for Measurements in the system table
Measurement translation rules
o Setting up measurement translation rules
o Difference between standard method and Use External rating
o Actions
Actual Measurements
o Entering manually
o Importing
o Entering on a WO
o Entering on a checksheet (Mobile)
o Understand the rating of a measurement
Inspection Control Board
o View completed Inspections
o Create Notification from Inspection
Notification Control Board
o View, sort, filter Notifications to find items that require action
o Communication workflow of a Notification
o Create Workorder from Notification