The Control Strategy popup allows you to determine the control strategy for the selected failure mode. How you interact with this popup is largely based on the data you entered on the Failure Mode Control Strategy Setup screen.
The following important attributes are available on this popup:
In the Occurrence section, you need to decide if the failure will be obvious (evident) to the equipment operators, or if the failure will be hidden from them. A leaking pump is usually evident because, say, the puddle of water on the ground gives it away. But if the pressure in the system exceeds the maximum allowable of 50 psi and the pressure gauge is broken and the gauge needle is stuck at 50 psi, which is indicating in the green range that pressure is normal when it actually is not, then it will not be evident to the operators there is a failure.
Evident: Select if the failure mode is evident or eventually becomes evident to the operating crew under normal circumstances.
Hidden: Select if the failure mode is hidden. The Failure only becomes evident to the operating crew if another abnormal event or failure also occurs.
Occurrence Note: Free text field for relevant notes.
In the Consequence section, you need to decide what consequences are associated to the failure mode. Will people get hurt or killed? Will environmental regulations be violated. Will it have adverse effects on your bottom line?
Safety: Select if the failure mode has safety consequences. Failures have safety consequences if they could injure or kill one or more people.
Environmental: Select if the failure mode has environmental consequences. Failures have environmental consequences if they could lead to breaches of corporate, regional, national, or international environmental standards or regulations.
Operational: Select if the failure mode has operational consequences. Failures have operational consequences if they affect production, output, product quality, customer service or operating costs in addition to the direct cost of repair.
Non-operational: Select if the failure mode has no serious consequences. Failures in this category do not affect safety, have no environmental impacts, nor pose production losses and involve only the direct cost of repair.
Consequence Note: Free text field for relevant notes.
Hovering over any of the checkboxes on this popup will bring up help text providing this is configured on the Failure Mode Control Strategy Setup screen. This help text is sensitive to the checkboxes already selected. For example, the Safety help text may differ depending on whether you selected Evident, Hidden, or none of them yet.
In the Control Strategy section, you can describe the method you want to use to control the failure mode. This typically would be a scheduled task, like PM Schedule, an on-condition task, or maybe a combination of tasks.
Control Method: This lookup shows all the control methods that were defined on the Failure Mode Control Strategy Setup screen. The lookup only shows values that match the selections made in the Occurrence and Consequence section of the popup. And changing any of the checkboxes in these two sections may clear the already selected control method if it does not have the newly selected checkboxes associated. Once a control method is selected the system will display the following values related to the control method.
Failure Finding checkbox - Failure Finding tasks involve testing hidden asset functions periodically to determine if an asset’s protective devices have already failed. This is very different to condition-based tasks that check the condition of something to see if it is in the process of failing.
Feasibility text - A proactive task’s technical feasibility is governed by the technical characteristics of the task and of the failure it is meant to prevent.
Worth Doing text - Whether a task is worth doing or not is governed by how well the Operating Crew thinks the task deals with the failure consequences.
Effectiveness text - If a proactive task cannot be found that is both technically feasible and worth doing, then suitable default actions must be taken.
Decision Guide text - Once a control method is selected the user is guided to what task should be executed.
Proposed Task: Free text field to describe the proposed task in detail. Some examples:
Scheduled PM: Replace motor filter MF7 with type AC-4 as per SOP SP106-7b.
Predictive PM or PdM: Visually inspect Exhaust Stack piping ES2 as per SOP 12. When some pitting or scaling is found, schedule a Work Order to follow PM #178.1 to refurbish exhaust stack piping. Possible inspection results: (1) Normal = No discoloration, no scaling, no pitting, (2) Warning = some discoloration, (3) Alarm = some pitting / scaling, (4) Critical = section loss
Failure-Finding Interval, FFI test: Function Test that the Exhaust System protective insulation is not torn after an intervention. Possible test results: (1) Pass = Exhaust System insulation not torn after intervention, (2) Fail = Exhaust System insulation torn after intervention
Run-To-Failure, RTF: No Scheduled Maintenance.
Redesign Types:
SOP – Update SOP SP106.a to include a soft-start ramp-up cycle before full GEN24 operation.
SMP - Write a PM that includes torque specifications for the exhaust manifold bolts on GEN-24.
Training - (Re)Train Millwrights who are required to perform magnetic particle testing on system hardware for SOP SP106.a.
Physical - Consider building a portable & deployable platform to enable safe inspection of gaskets by maintenance personnel.
This popup can be accessed from the Failure Modes popup on the RCM tab, the RCM Failure Mitigation tabs on the Equipment and RCM Templates screen and from the Failure Modes and Failure Mitigation tabs of the Case Management screen.