Riskbased Maintenance System Safety Analysis For Your Crane

Risk-based Maintenance System Safety Analysis For Your Crane xyz [as a generic & exemplified system] Results Overview Executive Summary Your Logo moergeli. com T F A Risk-based Maintenance (Rb. M) R D By Fault Tree Analysis (FTA) and G w e t v–i. Safety Reliability – Availability N– Maintainability r I o (RAMS) Analysis K e p R R e l Performing a O R a W n System Safety Analysis (SSA) r y e l t With a System Safety n Analysis Tool (SSAT) n I

Risk-based Maintenance (Rb. M) System Safety Analysis (SSA) Recommended Action Plan for Crane xyz moergeli. com 1. Retrofit or replace your Crane xyz as soon as possible: o Implement an Instantaneous Safety Program (ISP) o Continually monitor & evaluate condition in real-time o Continue to operate safely o Continually gather & evaluate missing RAM data 2. Perform Fault Tree/RAMS Analysis: o Verify & validate Safety: PL >= PLr(equired) o Increase Reliability by adding additional redundancy o Verify Availability: A > Ar by production goals o Verify Maintainability: Time slots/budgets >= MTTR 3. Perform System Safety Analysis (SSA): o Evaluate all production-critical systems o Select the most resilient & cost-effective options 2

Risk-based Maintenance (Rb. M) System Safety Analysis (SSA) Crane xyz - Key Results I By Fault Tree (FT) & RAMS Analysis moergeli. com Ø Safety is insufficient: PL ≈ a << PLr = d as required Ø No redundancy: All identified parts are A-Parts only (OR Gates only) Ø Availability ok: A > Ar based on your production goal Ø Maintainability ok: MTTR < Your planned time slots & budgets Ø Retrofit/Replacement Evaluation: Your Project Plan: Work in progress 3

Risk-based Maintenance (Rb. M) System Safety Analysis (SSA) Crane xyz - Key Results II By System Safety Analysis (SSA) moergeli. com 4 System SAFETY FIRST 1. Operate & monitor systems safely If and as far as systems are - and remain - safe, and 2. Evaluate potential alternatives … => Risk-based decision to select your preferred solution while continuing to operate & monitor systems safely: v Maintenance Plus (Option 0), or v Retrofit (Option I) by a Safety Case, or v Replacement (Option II)

Crane xyz Fault Tree & RAMS Analysis Results - Executive Summary Reliability – Availability – Maintainability – Safety (RAMS) Analysis By Fault Tree Analysis (FTA) moergeli. com 5

Crane xyz Fault Tree & RAMS Analysis Summary of Key Baselines I moergeli. com Ø FTA @ Level I (LI) Analysis (Closed Mode, “clean room”) Ø Common Cause Factors (CCF) excluded Ø Your process-oriented Level II Risk Assessment (LII RA) to verify … - Intended/foreseeable context, and - Process impacts, and - Risk mitigation/controls, and - Controlling potential for Common Cause Factors (CCF) 6

Crane xyz Fault Tree & RAMS Analysis Summary of Key Baselines II moergeli. com 7 Ø Crane Structure - Modeled & verified by project team - Limited to reasonable level of details by team’s decision (sound trade-off between additional value versus efforts) Ø Probabilistic approach & proprietary distributions for Maintainability (Monte Carlo Simulation, MCS) Ø MCS results verified by exact calculations (with limits) Ø All data used for FTA/RAMS provided & verified by

Crane xyz Fault Tree & RAMS Analysis RAM Tree – Results for F(ailure = 1 - R) per 1 year moergeli. com Probability for at least 1 failure per Analysis Period (AP = 1 year) = 0. 5768 ≈ 58% => Reliability ≈ 42% 8

Crane xyz Fault Tree & RAMS Analysis Safety Tree – Results for F(ailure = 1 - R) per 1 hr moergeli. com Probability for at least 1 failure per Analysis Period (1 hour) = 3. 764 *10 -5 ≈ 4 Failures/100’ 000 operating hours ≈ Performance Level a (by ISO 13849 -1: 2015) 9

Crane xyz Fault Tree & RAMS Analysis Summary Discussion of Results moergeli. com 10 Crane xyz was commissioned per … => CE Conformity Assessment & documentation FTA @ Level I (LI) Analysis (“in clean room”) v OR Gates only (No AND Gates) => No Redundancy v All Primary/Basic Events lead to system failure => High number of minimal cuts => A-Parts only v Additional Bow Tie Analysis (BTA) recommended to include risk mitigation/control at Level II (LII)

Crane xyz Fault Tree & RAMS Analysis Identified Current Limits of Analysis Fault Tree Analysis (FTA) & RAMS: Ø Limited available operational data for R & A Ø Limited available cost information for MTTR Ø Limited available data of SRP/CS Ø … System Safety Analysis (SSA): v Limited MTTFd/MTBFd data available by manufacturer v Crane’s B 10 cycles verified with available moergeli. com 11

Crane xyz Fault Tree & RAMS Analysis Targeted Scope & Added Value by this Analysis moergeli. com 12 Scope: Demonstrate quick wins of a Risk-based Maintenance (Rb. M) Analysis (Reliability, Availability, Maintainability & Safety, RAMS Analysis) => Identify critical paths to system failure (= Minimal Cuts) => Classify A-B-C parts by reliability => Action Plan for a risk-based Maintenance Program Added Value: + Increase (or, at least, maintain analyzed) Reliability (R) + Increase (or, at least, maintain analyzed) Availability (A) + Increase (or, at least, maintain analyzed level of) Safety (S) => Optimize time/intervals & cost of Maintenance (M) => Realize next steps for tomorrow’s smart manufacturing

Crane xyz Fault Tree & RAMS Analysis Achieved Scope & Added Value by this Analysis moergeli. com 13 Scope: Demonstrate quick wins of a Risk-based Maintenance (Rb. M) Analysis: => Reliability, Availability, Maintainability & Safety (RAMS) Analysis: Done => Identify critical paths to system failure: Done => Classify A – (B – C) parts by reliability: Done => Action Plan for risk-based Maintenance Program: Pending Added Value: + Increase (or, at least, maintain analyzed) - Reliability (R): Pending - Availability (A): ok - Safety (S): Pending (Instantaneous Safety Program) + Optimize time/intervals & cost of Maintenance: Pending + Realize steps for smart (IIo. T) manufacturing: Pending

Crane xyz System Safety Analysis (SSA) moergeli. com 14 System Safety Analysis (SSA) By a Specific Tool (SSA/T)

Crane xyz System Safety Analysis (SSA) Recommendations for risk-based decision-making … 15 v Safety First: PL >= PLr = … ? (based on Level II Risk Assessment, RA) [Performance Level as-built >= Performance Level required] v A >= Ar by production goals …? [Availability >= Availability required for production goals] v MTTR <= Available time slots & budgets Mean Time To Repair/Replace <= Available time/money …? moergeli. com

System Safety Analysis Tool (SSAT) Priorities by Decision Workflow moergeli. com 1. Safe ? 1. System Safety ok? ØPL >= PLr ? 16 NO Yes 2. Productive ? 2. Availability ok? NO ØA >= Ar by production goals? 3. Economic ? 3. Maintenance Time/Cost ok? NO ØMTTR <= Available slots & budgets Yes Continue to operate v Maintenance Plus (Option 0), or v Retrofit (Option I), or v Replace (Option II) Any. . . 4. Roadmap / Project Plan

Risk-based Maintenance (Rb. M) System Safety Analysis (SSA) Your Value Added Your Logo moergeli. com 1 7 Pros – Your Benefits … Ø Support for your risk-based decision-making Ø Your maintenance tailored to your risks, as much as needed Ø Your risk-based options: Maintenance+ / Retrofit / Replace Ø Applicable to all kind of your (technical) systems Ø Delivering quantitative, transparent & auditable results Ø Scalable – independent of project task/size, time & money Cons – Your Limitations as you will need … Ø (Technical) Systems with minimal functional descriptions Ø Minimal data from your Operations & Maintenance (O&M) Ø A competent team, including experienced O&M staff No substitution by algorithms, robots, Artificial Intelligence (AI) & the like Ø Some (of your precious) time & money… as always

Risk-based Maintenance (Rb. M) By System Safety Analysis (SSA) For Further Reading - Selected Publications … moergeli. com 18 Ø BGIA Report 2/2008 e Functional Safety https: //www. dguv. de/medien/ifa/en/pub/rep/pdf/rep 07/biar 0208/rep 2 2008 e. pdf Ø Sverdrup Scrapbook by P. L. Clemens, 2002 http: //isss-tvc. org/scrapbook. pdf Ø RAMS Flyer by Risk. Consult (RC) & moergeli+moergeli consulting engineering (mm) https: //www. moergeli. com/en/cat-risk-management-3/integral-ramsanalysis-category Ø World Tunnel Congress (WTC) 2016 by Sander, Moergeli, Reilly https: //moergeli. com/en/cat-risk-management-3/60 -correlation-anddependencies-ii Ø RIAAT (Risk Analysis and Administration Tool), Software by RC https: //www. riaatsoftware. com/

Risk-based Maintenance (Rb. M) By System Safety Analysis (SSA) Selected Reference Standards … Ø ISO 31000: 2018 Generic Risk Management https: //www. iso. org/iso-31000 -risk-management. html Ø ISO 12100: 2015 Safety of Machinery - Risk Assessment https: //www. iso. org/standard/51528. html Ø ISO 13849 -1: 2015 Safety-related Parts of Control Systems (SRP/CS) – Part 1 https: //www. iso. org/search. html? q=13849 -1 Ø ISO 31010: 2009 Risk Management – Risk Assessment Techniques https: //www. iso. org/standard/51073. html Ø … [and others] moergeli. com 19