WF33: Assign Maintenance Action

Pre-requisites

• FBD Model: Required to assign RCM data e.g. failure diagrams, criticality, reliability.
• Maintenance Approach (outside of MADE): either current maintenance or a historical database for costs and tasks.

Detailed Descriptions (numbered steps)

1. Right-click a model item and click "Maintenance Actions" from the context menu.
2. Determine if model item will have "Manual Restorative MTTR" under "Maintenance Time Calculation" section. If so, enter MTTR value directly in the field provided. If not, proceed to next step. 3a. Enter the MTTR into the Maintenance Time Calculation MTTR field. 3b. Select the "+" icon to create a new Maintenance Action.
3. Define the details of the maintenance action by typing in the respective fields (e.g. name, ID and description).
4. Select a maintenance type, location and define action intervals from the drop-down boxes. Tick continuous monitoring check box as needed.
5. If the maintenance type is condition-based, establish inspection and maintenance tasks; if not, then establish only the maintenance tasks. Use the tabs to navigate between Maintenance and Inspections as needed. Create the necessary tasks, personnel and items (including spares and consumables) by selecting the "Box", "Human" and "Cog" icons respectively.
6. Define the duration for each task, the cost and number of each personnel and the quantity and cost of each item used in the maintenance. Tick or untick the Downtime check-box for each new task created.
7. Establish clear associations between failure modes and the corresponding maintenance actions defined for them.
8. Review the Maintenance Action to determine whether the details, type, tasks and parameters are correct. If so, then proceed to assign the maintenance actions. If not, create additional Maintenance Actions.
9. Select active maintenance actions by using the provided checkboxes. Select the Restorative Maintenance Action by using it as the MTTR source in the top-left corner drop-down menu.

Fields referenced in the diagram

• Define Action Details: Action ID, Action Name, Description
• Select Action Type: Maintenance Type, Location, Intervals/Monitoring
• Define Inspection/Maintenance Tasks: Task, Personnel, Item
• Define Task Parameters: Downtime, Duration, Cost, Quantity

Decision points

• Manual Restorative MTTR? — Yes → Direct Entry MTTR; No → Create New Maintenance Action.
• All Maintenance Actions Defined? — No → loop back to Create New Maintenance Action; Yes → Assign Maintenance Action.

Outputs

• Maintenance Action Table: A table that details the maintenance tasks, personnel, spares and consumables required to complete the action.
• Item Maintenance Report: A report that summarises all of the maintenance being performed on a selected item.

Screenshot walkthrough (captions/labels extracted)

Step 1: Open Maintenance Actions

• System Model viewer showing "Coupling 1" (context menu open), "Lift Pu[mp]", "Engine", "Injector Pump" nodes with flow arrows to "OUT". Context menu on Coupling 1: System Model, Failure Diagram, Functions, RBD Model, Back-Fit RCM, Maintenance Actions (highlighted), Markov Analysis, Cut/Copy/Paste, Delete, Zoom In/Out, End Effect Item, Response Paths, Monte Carlo, Propagate All..., Override Failure Diagram, Failure Injection, Response Simulation, Load from Library, Save to Library, Advanced Properties.
• "Coupling 1" Maintenance Actions editor: left nav Overview, Maintenance Actions (selected), Product Characteristics. "Maintenance Time Calculation": "Specify the MTTR (MCMT) by manual entry or select a source Maintenance Action. MPMT and MMT are calculated based on assigned tasks." Restorative Action "Manual MTTR", MTTR (hrs) "1.00". "Maintenance Action Details": Action ID, Maintenance Type dropdown, Action Name, checkbox Continuous Monitoring, Description, Maintenance interval (hours), Location of Maintenance dropdown, Inspection interval (hours), CCMR checkbox, Effectiveness Factor. Tabs: Maintenance (Tasks and Personnel / Equipment and Consumab...) / Inspection (Tasks and Personnel / Equipment and Consumab...). Table columns: ID/Task Name/Downtime/Duration (hrs)/Rate (USD/person/hr)/# Personnel/Total (USD) — empty.

Step 3a: Direct Entry MTTR

• "Maintenance Time Calculation" panel: "Specify the MTTR (MCMT) by manual entry or select a source Maintenance Action. MPMT and MMT are calculated based on assigned tasks." Restorative Action dropdown "Manual MTTR", MTTR (hrs) "1.00".

Step 3: Create New Action

• "Coupling 1" editor: left nav Overview, Maintenance Actions (selected), Product Characteristics. "Maintenance Time Calculation": Restorative Action "Manual MTTR", MTTR (hrs) "1.00". "Maintenance Actions": "Maintenance Actions assigned to this item. Multiple preventative actions may be assigned in conjunction with a corrective task." List (empty) with add "+" icon highlighted, plus copy/export/reorder/sort/delete icons. "Maintenance Action Details" panel (right, empty fields): Action ID, Action Name, Description, Location of Maintenance, CCMR, Maintenance Type, Continuous Monitoring, Maintenance interval (hours), Inspection interval (hours), Effectiveness Factor. Tabs Maintenance (Tasks and Personnel/Equipment and Consumabl...) / Inspection (Tasks and Personnel/Equipment and Consumabl...) / Linked Failures / Summary. Empty task table.

Step 4: Define Action Details

• "Maintenance Action Details" panel (blank template): Action ID, Action Name, Description (multi-line), Location of Maintenance dropdown with gear icon, CCMR checkbox; Maintenance Type dropdown with gear icon, checkbox Continuous Monitoring, Maintenance interval (hours dropdown), Inspection interval (hours dropdown), Effectiveness Factor.

Step 5: Select Action Type & Intervals

• "Maintenance Action Details": Action ID "003", Action Name "Coupling Repair", Description "Condition-based repair for coupling.", Location of Maintenance "Field", CCMR checkbox. Maintenance Type dropdown expanded: Breakdown - Repair, Breakdown - Replace, Failure Finding, Scheduled - Repair, Scheduled - Replace, Scheduled - Service, Scheduled - Lubrication, Scheduled - Inspection, "Condition-based - Repair" (highlighted/selected), Condition-based - Replace, Condition-based - Service, Condition-based - Lubrication. Maintenance interval, Inspection interval, Effectiveness Factor fields.
• Second instance: Maintenance Type "Condition-based - Repair" selected; Maintenance interval "0.000 hours", Inspection interval "0.000 hours" (highlighted), Effectiveness Factor "0.00E+00". Tabs Maintenance/Maintenance/Inspection/Inspection visible below.

Step 6: Define Inspection/Maintenance Tasks

• Four tab states shown: "Maintenance - Tasks and Personnel" (highlighted) — table (ID/Description/Downtime/Duration (hrs)/Rate (AUD/person/hr)/# Personnel/Total (AUD)) with "Add a new Maintenance Task" tooltip on add icon, empty table; other tabs Maintenance-Equipment and Consumables, Inspection-Tasks and Personnel, Inspection-Equipment and Consumables, Linked Failures ("2 of 2 Failures linked"), Summary ("0.00 hrs / $0.00") shown alternately highlighted with matching empty tables and "Add a new Maintenance Item"/"Add a new Inspection Task"/"Add a new Inspection Item" tooltips.

Step 7: Define Task Parameters

• "Maintenance - Tasks and Personnel" tab: table populated: 001 "Task A" (Downtime checked, Duration 1.00, Rate $50.00, # Personnel 2, Total $100.00) with sub-row "001 Personnel A" ($50.00, 2, $100.00). "Linked Failures" shows "2 of 2 Failures linked", "Summary" shows "1.00 hrs / $500.00".
• "Maintenance - Equipment and Consumables" tab: table (Item ID/Item Name/Cost (AUD)/Quantity/Total (AUD)): "001 Item A" ($400.00, 1.00, $400.00). Summary "1.00 hrs / $500.00".

Step 8: Link Failures

• "Linked Failures" tab: table (Failure/Failure Path): "Couple Mechanical - rotational Angular velocity Low (Coupling 1)" (checked, expanded) > "Fractured (Coupling 1)" (checked, Failure Path "Fractured (Coupling 1) → Couple Mechanical - rotational Angular velocity Low (Coupling 1)"), "Twisted (Coupling 1)" (checked, Failure Path "Twisted (Coupling 1) → Couple Mechanical - rotational Angular velocity Low (Coupling 1)"). Tab header shows "2 of 2 Failures linked", Summary "1.00 hrs / $0.00".

Step 9: Assign Maintenance Action

• "Maintenance Time Calculation": Restorative Action dropdown expanded: Manual MTTR, Linked Failure(s) MTTR, "002 - New Action" (highlighted/selected). "Maintenance Actions" list: checkboxes — "001 - New Action" (unchecked), "002 - New Action" (checked, highlighted), "003 - Coupling Repair" (unchecked). "Maintenance Action Details": Action ID "002", Action Name "New Action", Description (empty), Location of Maintenance "Field", CCMR checkbox. Tabs: Maintenance-Tasks and Personnel (selected), Maintenance-Equipment and Consumabl..., Inspection-Tasks and Personnel (greyed/disabled). "Failure" table: "Couple Mechanical - rotational Angular velocity Low (Coupling 1)" (unchecked) > "Fractured (Coupling 1)" (checked, Failure Path "Fractured (Cou..."), "Twisted (Coupling 1)" (checked, Failure Path "Twisted (Coup...").