1C:RCM Reliability Management

Main article: RCM (Reliability Centered Maintenance)

The 1C:RCM Reliability Management product is designed to optimize preventive and diagnostic asset maintenance programs at enterprises in various industries. It is based on the RCM (Reliability-Centered Maintenance) methodology.

The purpose of the 1C:RCM is to create an optimal service program necessary to ensure a given level of reliability of fixed assets at a minimum cost.

2023

1C:RCM 1.0.20.1

On December 25, 2023, the developer company Desnol Soft announced the release of 1C:RCM Reliability Management "1.0.20.1. The solution helps large businesses build an effective maintenance program to optimize maintenance costs while ensuring the required reliability of the equipment.

1C:RCM 1.0.20.1

According to the company, in 2019, the developer company Desnol Soft released an expert system of the RCM class, developed on the 1C: Enterprise platform. The 1C:RCM Reliability Management solution is based on the RCM (Reliability-centered maintenance) methodology, which means reliability-oriented service in English. The methodology is based on an RCM analysis, which is an algorithm of certain actions to assess the reliability of equipment, the cost of service options and the risks of asset management in the context of each object of operation. The object of operation can be both a piece of equipment and its component - units, units.

1C:RCM integrates with "1C:ERP Enterprise Management 2" and the 1S:TOIR ecosystem solution - "1S:TOIR Repair and Maintenance Management of KORP Equipment." All products of the 1S:TOIR ecosystem, which also includes 1C:RCM, were developed by Desnol Soft, the Russian center of competence for the digitalization of MR processes. The 1C:RCM capabilities are strengthened by the predictive analytics service. It uses machine learning technology and helps predict failures based on anomalies (deviations) in the readings of equipment sensors.

The procedure for working with information for conducting RCM analysis in the 1C:RCM begins with the purpose - for which the company purchased certain equipment, what function the object of operation provides. In the RCM methodology, it is important to present the equipment or the equipment node base by functional location. For example, there is a function of pumping water. In this case, pumps will be tied to the functional place, which ensure the transfer of water. Next, the RCM methodology calls for an answer to the question of when an asset ceases to perform its functions and what is a functional failure. Each feature has a performance standard. As a performance standard, you can specify, for example, the amount of water pumped in a given time. If this performance standard is violated, it is called functional failure.

The event itself or the cause of a functional failure is commonly referred to as a failure mode. For example, such an event could be coupling wear or filter mesh blockage. Is it necessary to specify the cause of the failure and carry out RCM analysis for all facilities? The RCM analysis is carried out on equipment critical for production, the failure of which or downtime can seriously affect the economic results of the company.

Thus, for an enterprise engaged in the operation of gas turbine power plants (gas turbine power plants), the most critical objects of operation may be a gas turbine installation, a gas turbine unit and a gas compressor - equipment and its components that are responsible for life support and uninterrupted operation of gas turbine power plants. Such equipment plays a key role not only in the production economy, but also in issues of ecology and human safety. It is on the basis of these three categories that the severity of the consequences in the 1C:RCM is indicated. It plays a key role in determining the most critical operating objects in the updated workplace "Assessment of the criticality of analysis objects."

The workplace "Assessment of the criticality of analysis objects" appeared in a previous release 1C:RCM following the need of reliability specialists to see the separation of operation objects by the degree of criticality. Previously, in the workplace "Assessment of criticality of analysis objects," it was possible to manually compare the criticality of an object based on functional requirements. Such requirements may include, for example, protecting personnel from poisoning, protecting the environment from contamination, releasing and producing sulfuric acid, or ensuring the storage of sulfuric acid.

In the release of 1C:RCM 1.0.20.1, for each functional requirement, the user will see the consequences and severity of the consequences. In the event of protection of personnel from poisoning, the consequence will be penalties for safety violations, the severity of the consequences - 3 million rubles. In case of environmental protection from pollution by consequence penalties for environmental pollution will become, the severity of the consequences will be 13 million rubles.

The cost of severity of consequences is the basis for the automatic determination of the most critical objects of operation. Now the functionality of the updated workplace "Evaluation of criticality of analysis objects" saves users time and solves one of the main requests at the initial stage of work in the system.

Based on the selection of the most critical objects, an RCM analysis is built. Important information here will be data on the functions of operating objects, failures, types, consequences, probability and frequency of failure modes occurrence. This data will help to conduct a risk analysis, as well as see in the system which operating objects have permissible and which - unacceptable risks in order to form a program for servicing those operating objects for which risks are unacceptable. Information on operating objects, types of failures, strategies and service options is available in the workplace "Formation of service options." It replaced the workplace "Analysis." 1C:RCM users can now choose strategies and add service options without switching between workplaces.

The maintenance strategy is selected from the entire list of strategies or from decision diagrams that are based on GOST or international maintenance standards for reliability, such as SAE 1012. Users can create and use their solution diagrams, as well as add maintenance strategies for operating objects.

Once you have defined a strategy, such as planned replacement, scheduled repair, or work-to-failure, you can add maintenance options for the facility. They include activities (maintenance or diagnostics) and activities (monitoring of the main and backup power supply, monitoring of the presence of extraneous vibrations), as well as information on the frequency their implementation and the expected effect of mitigating the risk of a particular type of failure. The expected effect is the updated probability and severity of failure mode consequences. Based on these two parameters, the system calculates the failure mode risk.

In the release of 1C:RCM 1.0.20.1, it became possible to make a more balanced and informed decision when choosing a particular service program. Now the user can compare two service options in the updated workplace "Service Program Generation." The option that was selected by the user and the option that the system recommends using based on the highest performance indicator - ROI (the indicator was introduced in this release) are compared.

In the updated place "Service Program Generation," the user can also compare two service options by the composition of activities. Data on the composition of operations are stored in the "Operations of Measures" reference book, which is comparable to the "Process Operations" reference book in the KOP 1S:TOIR. In addition, when comparing two options, the user will see information about the frequency of the events, as well as the expected effect of mitigating the risk of failure mode. Together with the release of 1C:RCM 1.0.20.1, two reports appeared - "Equipment Criticality" and "Failure Criticality." The first report reflects information about the objects of operation, the total type of failures, as well as the cost of the consequences of failure modes. In the second Failure Mode Criticality report, the user will see the original risks of functional failures in the context of the most critical operating facilities.

Technical issues related to the release of 1.0.20.1:

• version "1C: Libraries of standard subsystems" in the 1C:RCM has been updated to 3.1.9.162. To work in the system, the version of the 1C: Enterprise platform is required at least 8.3.21.1775, 8.3.22.1923;
• release 1C:RCM is intended for use with the software product "1C: Configuration Licensing and Protection System" version at least 3.0.33.11307.

1C:RCM release 1.0.18.1

On May 15, 2023, Desnol Soft announced the release of the updated release of the 1C:RCM Reliability Management system. The system implements a risk-oriented approach to asset maintenance, ensuring RCM analysis and the formation of an optimized, that is, more profitable, MR program, subject to all necessary reliability measures.

According to the company, traditionally the equipment maintenance program is based on the manufacturer's passport data , where maintenance measures and their frequency are prescribed, on the basis of which the WEP schedule is built. RCM analysis "looks" at production in terms sight of possible risks and the price of their consequences, helping to create a more efficient service program - both in terms of finance reliability.

To perform an RCM analysis in 1C:RCM Reliability Management, you need to download data on critical repair objects (for example, from an EAM or ERP system). During the analysis, risk calculation and ranking are carried out, an optimally beneficial maintenance strategy is selected, an optimized maintenance and repair program is assembled (with a list of necessary measures and the frequency of their implementation). The collected program goes through the rationalization stage, where duplicate and replaceable activities are detected. Then the optimized MR program, taking into account the risks and the likelihood of their occurrence, is transferred for execution back to the EAM or ERP system.

The system "1C:RCM Reliability Management" is integrated with the EAM solution "1S:TOIR Repair and Maintenance Management of KORP Equipment" as well as with the enterprise resource management program "1C:ERP Enterprise Management."

In the updated release, important changes have 1C:RCM appeared that help optimize the quality of RCM analysis, make it more complete and consistent, and the MRO program created on its basis is more rational and effective.

RCM analysis is usually carried out for critical equipment because it has the greatest impact on the processes and safety of the enterprise. Many factors - such as the presence of hazardous substances, a large number of personnel, public interest in safety, loss of productivity and optimal wear resistance of equipment - make critical equipment key to ensuring environmental safety, staff health and profit. Conducting an RCM analysis helps identify and analyze potential risks and then create better service strategies.

With the release of 1.0.18.1, an updated workplace "Assessment of criticality of analysis objects" appeared in the 1C:RCM to determine the criticality of service objects. This work center allows you to determine the criticality of the equipment hierarchy elements, for each of which its criticality value can be specified.

The work center displays the risk matrix, equipment hierarchy, and functional requirements of the objects. The matrix is used to assess the criticality of the risk, the criticality value determines the risk categories.

Assessment of criticality of analysis objects

In the 1C:RCM criticality system, the following is displayed:

• when selecting systems to analyze (in the analysis project),
• in the Define Analysis Object List work center
• in the workplace "Equipment inspection,"
• in the workplace "Service Program Development."

In this release, the approach to conducting RCM analysis has been slightly changed.

The process is now divided into three stages:

• entering failure modes and determining their criticality,
• generation of service program variants,
• formation of an optimal service program.

Input of failure modes and determination of their criticality is carried out in the updated workplace "Equipment inspection." In a few steps, the user will determine: possible equipment failures, failure modes, the probability of occurrence and severity of the consequences of failure modes, as well as the risk of failure modes. Based on the calculated risk of failure modes and system settings, failure modes can be classified as "critical" or "non-critical."

The data specified in this workplace is "general" and does not need to be re-entered when performing various RCM analyses on the selected equipment.

Inspection of equipment

Development of service program options is carried out in the updated workplace "General Analysis." Service program options are generated for single failure modes with the expected effect. There may be several such options, they may differ in the composition of events, their frequency and the expected effect.

Conduct General Analysis

The "Service Program Generation" workplace allows you to select one of the service program options. To do this, the list of failure modes of the selected object, the consequences of failure modes, the selected maintenance program and the composition of its activities are displayed. When choosing a work program, you can see the results of the comparison of options, differences in the composition of tasks, frequency and the expected effect - they are highlighted in red.

Service Program Development

To improve the ease of use, two reports have been added to the system:

• "Equipment failure types" - a list of failure types, their probability and cost of consequences is displayed in the report;
• "Equipment Survey Level" - The report demonstrates the total number of failure modes entered, examined and critical, and makes it possible to quickly assess the degree of examination.

The 1C:RCM system is complemented by a predictive analytics service. The "smart" service uses machine learning technologies to predict failures based on an analysis of anomalies (deviations) in the operation of equipment.

Program Maintenance Program Generation Program Comparison

The joint application of 1C:RCM and predictive analytics service to increase the efficiency of MRO management gives the following:

• Optimization of productivity, production volume and quality of products (service).
• Increase the efficiency of maintenance costs.
• Extending the life of expensive and difficult-to-replace assets.

RCM analysis and predictive analytics help reduce the risk of equipment failures (including potential ones) and reduce the number of breakdowns. Equipment reliability and integrity analysis allows for maintenance at the most efficient point in time, identification of critical elements, selection of the most effective types of maintenance for each of them and determination of the optimal type and frequency of maintenance and replacement of components. This helps to avoid downtime, loss of capacity, disruption of technology, reduction in the quality of products and the costs associated with this. Thus, the RCM analysis takes into account the specific operating conditions of the equipment, focuses on the types of maintenance that have the greatest effect on performance and is aimed at optimizing maintenance on a case-by-case basis.

2022: 1C:RCM Release 1.0.16.1

On December 22, 2022, Desnol Soft announced the release of 1S:TOIR KORP 3.0.3.1. The changes also affected other elements of the ecosystem - the Mobile Brigade application and the 1C:RCM Reliability Management system. Read more here.

According to the company, an important element of the MR ecosystem is the 1C:RCM Repair Management system. This software solution is designed to provide a proactive approach to critical asset management that aims to reduce maintenance costs while maintaining the required level of reliability. The main tool of the system is RCM analysis, which results in an optimized MR program - "cheaper" and "no less reliable," which takes into account both risks and their cost, and is also designed to reduce or even completely eliminate the likelihood of failures or, at a minimum, reduce the severity of their consequences.

In order to facilitate the preparation process for RCM analysis related to the determination of the list of the most critical equipment, an automated workplace for criticality assessment has appeared in 1C:RCM version 1.0.16.1. AWS helps to assess the criticality of equipment units and their units. You can then rank the equipment by criticality and select the equipment group most in need of RCM analysis.

The criticality assessment workplace displays the risk matrix, equipment hierarchy and specified equipment functions. Each piece of equipment can be assigned a specific criticality value from the selected risk matrix. Equipment criticality is displayed in the RCM Analysis Project when systems are selected for analysis and in the Define Analysis Object List workplace.

An important point is that repair objects for criticality determination and subsequent analysis can be unloaded into the 1C:RCM from the BCC 1S:TOIR or any other EAM system. And the optimized maintenance and repair program, built as a result of RCM analysis, is loaded back into the 1S:TOIR CORP (or other EAM system) for the implementation of measures.

2021: Description of the 1C:RCM

According to information for November 2021, the product includes:

• tools for RCM analysis, which allow you to determine possible failure modes, their parameters and draw up a service program taking into account the risk of possible failure modes;
• predictive analytics subsystem that allows you to obtain anomaly data and automatically classify it into evolving failure modes.

The basis for 1C:RCM operation is information about the repair facilities at the enterprise and the maintenance standards established for them. The 1C:RCM provides reference books for storing information, automated workplaces for convenient entry of data into the system and its management.

1C:RCM has built-in mechanisms:

• for exchange with information systems 1C:ERP Enterprise Management 2.0 and "1S:TOIR Management of Repair and Maintenance of 2 KORP Equipment"
• to download data from 1S:TOIR Repair and Maintenance Management version 1.3.

RCM analysis relies on structured and formalized information that can be obtained from these programs using built-in integration mechanisms. It is also possible to download data EAMERP from/-systems of other manufacturers through additional integration or through the integrated loading mechanisms in the 1C:RCM from. files Excel Manual data entry is possible if necessary.

During the RCM analysis, the following steps are performed:

• Preparation of data for analysis - formation of regulatory reference information on objects of analysis, determination of logical and functional models of systems and subsystems, formation of reliability structure.
• Failure analysis (FMEA/FMECA) - determination of critical equipment for analysis, determination of failure modes and probability of their occurrence, determination of possible consequences of failures and their severity, formation of risk matrix, determination of failure criticality, determination of reliability parameters, reporting.
• Formation of the optimal MR program - determination of the necessary measures, selection of the most effective service strategy with determination of its estimated cost, construction of the MR program, optimization of the activities.
• Analysis of measures effectiveness - analysis of RCM measures effectiveness, transfer of the formed MR program for execution to the repair and maintenance management system (EAM/ERP system), correction of the MR program.

Based on the results of the RCM analysis, the client receives a maintenance and repair program formed from rational measures and cost-effective strategies, comprehensively tested in terms of efficiency and reduction of any risks. The optimized MRO program is transmitted from the 1C:RCM to the ECC 1S:TOIR 2 or another EAM class system.

Users

Users of 1C:RCM can be:

• technical management of enterprises,
• reliability engineers,
• risk managers,
• specialists of the chief mechanic and chief power engineer service,
• Instrumentation Department Specialists,
• specialists of the technical supervision department,
• specialists of the planning and technical department.

Features

According to the developers, the use of the product allows you to increase the efficiency of the operation of fixed assets of the enterprise and contributes to:

• increase of equipment availability and reliability at minimum costs,
• improving safety,
• reducing the risk of accidents and accidents,
• increase of equipment service life,
• Optimize total cost of ownership (TCO)

2020

Predictive Analytics Module

October 14, 2020 system: 1CRCM supplemented by the module. predictive analytics

Release of the first release 1C:RCM

On March 19, 2020, the developer Desnol Soft released the first release of 1C:RCM Reliability Management "1.0.8.1.