MADe
A 1D Solution which can predict the design, safety, reliability and health management of advanced complex systems in various industry application
OVERVIEW
Maintenance Aware Design Environment
“ You cannot expect to meet the challenges of today with yesterday’s tools, and expect to be in business tomorrow”
In today’s world Contemporary businesses face a unique set of challenges, which require more capital injection against a backdrop of increasing operational costs. Some of these challenges range from disruptive technology, growing size of business facilities, expanded business operations with an international focus, increasing demand for quality from users, demand for more efficiency to meet shifting user expectations and many others.
Faced with these challenges, it is important for every business to adopt a new approach starting with the basics. This is where a Reliability, Availability and Maintainability (RAM) system comes into place. There is general agreements that as companies expand, asset management and operations is becoming a nightmare.
If a constituent component is failing, then it is logical that it will have an impact on the overall performance hence the need to determine the actual quantification of this impact. Quantitative analysis of reliability and recommendation of the best way to achieve optimal reliability levels is also part of a RAM process.
Once the RAM analysis is complete, there is more data to rely on in decision making. The data generated will also come in handy in improving overall system efficiency, which is what every business today needs. Ultimately, RAMs leads to optimal performance and this improves the bottom-line. Identifying the weak links in the system using concrete data leads to gradual improvement.
MADe
It improves the quality of decision making at every step of a system’s lifecycle (Bid / Proposal, Acquisition, Design, and Sustainment / Asset Management)
Maintenance Aware Design, is an engineering risk management and decision support solution that brings Reliability, Availability, Maintenance and Safety (RAMS) into the product lifecycle. MADe part of Siemens Simcenter 1D solution developed by PHM Technology is an advanced engineering software which can predict the design, safety, reliability and health management of advanced complex systems in various industry application.
MADe uses simulation techniques to consistently identify and mitigate engineering risk based on the potential technical, capability, and economic consequences. It does this concurrently with the design process to ensure that safety and reliability problems are identified early and considered throughout the development process (vs just before going to manufacturing) so can be resolved before they are designed into the product.
Why MADe?
Now a days the systems and subsystems involved in modern industry are becoming more and more complex as they increasingly combines electronics, hydraulics, mechanical components and sub-systems comprising thousands of moving parts.
The increasing complexity of the system will make it difficult for an engineer to manually map the dependencies of failures between hierarchies and domains and therefore to identify potential risks. This is a strong driver for OEMs to introduce technology like MADe which will helps reduce the complexity of the process for the engineer by ensuring that dependency modeling is achieved ‘automatically’ throughout the system rather than relying on the engineer.
Increasingly OEMs are devolving design responsibility to their design partners and lower-tier suppliers while they focus on systems engineering and integration. However, a key issue for the OEMs is that they then use the design / failures data generated by their partners as the basis for analyzing reliability and developing diagnostic capabilities. This process has to be done manually due to the lack of integration because of less consistency in the data due to the variation in methodology. Therefore, there are strong drivers for the OEM to introduce technology that can increase standardization into the design process in order to improve quality and analysis capabilities.
Significant variances develop in the support costs associated with complex systems, often because the costs of support are not considered appropriately during the design phase. MADe provides the potential to “Design for Support” instead of simply supporting the design based on its support of concurrent engineering practice to consider the Supportability Influence
Also referred to as Vendor Based Logistics (VBL) effectively transfers the financial risk of operating and maintaining equipment from the customer to the OEM. PBC means that OEMs are increasingly focused on technologies that can assist them to increase the reliability of their systems and therefore decrease the maintenance / logistics footprint required to support them (the major component of cost of ownership).
Implementation of MADe at any stage of the product lifecycle will generate a set of benefits:
Operational
- Optimize system availability (Readiness)
- Minimize downtime (Mission impact)
- Ensure ‘safe as practical’ operations
- Engineering decision support for supportability analysis
Cost
- Optimize cost of ownership
- Reduce the cost of engineering analyses (accelerate productivity)
- Reduce the schedule impact of engineering analyses
- Technical decision support for economic trade studies
Process
- Design / Acquire / Operate with support considerations
- Traceability of analysis across the product lifecycle
- Knowledge capture / management across the product lifecycle
- Model-based decision support with engineering analysis
MADe Modelling is used to create a model of a system to identify the expected behavior and the impact of potential failures and risks associated with a configuration in an objective, repeatable and traceable process. The engineer can document how a system is expected to be used (Mission Profile Definition), where the system will be used (Environmental Scaling Impact) and this information is utilized to generate dynamic charting outputs and a FMEA report which will indicate detection means, compensating provisions and severity classification. MADe Modelling is consistent with Systems Engineering principles, can be integrated with CAD / PLM systems, and effectively implemented at any stage of the product lifecycle.
MADe Safety and Risk Assessment (SRA) is used to analyze and understand the criticality of functional risks in a design configuration, and to establish and document the potential impact of failures on operations and the cost of ownership. Criticality parameters for component functions and their associated failure concepts are defined by the user to support automated generation of a range of safety and risk assessments that are required for the design and support of safety / mission critical equipment, including FMECA & Functional Fault Tree Analysis.
MADe Reliability, Availability & Maintainability (RAM) module is used to assess when failures in a system are expected to occur, how best to mitigate their risk and how this will impact system cost, safety and availability. To achieve this, the RAM module enables users to apply different reliability analyses to calculate the likelihood of failure at any stage of the product lifecycle. A range of standards compliant with maintenance analysis ensures that the maintenance approach is technically valid and economically justified.
![](https://www.aetos.co.in/wp-content/uploads/2020/12/made-phm.png")
The PHM module is used to design/validate the diagnostic requirements for Condition Based Maintenance (CBM) of complex systems in an integrated analysis solution. User defined and automatically designed sensor sets are analyzed for diagnostic coverage and probability of detection. It enables optimization of sensor selections based on failure mode coverage and metrics (cost and weight). The key question the model aims to address is whether any specific sensor “buys its way onto the system.” This module is used to analyze and assess a system’s sensing capability.
Applications
It is well known that reliability of aircraft equipment is very important to aircraft during the flight because performance of aircraft product can affect flight safe directly. In order to make the equipment work normally, FMECA is applied in an aircraft equipment to analyze its reliability and improve operational reliability of the product.
![](https://www.aetos.co.in/wp-content/uploads/2020/12/aero2.png")
MADe provides a consolidated modelling and analysis solution that results in improved data quality from suppliers and ‘a single point of truth’ system model that is easier to integrate with on-going configuration management processes
There is a requirement to utilize engineering tools that have the appropriate data quality, usability, integrity, currency and knowledge capture capabilities to ensure accurate engineering modelling and analysis.
Shrinking national defence budgets, increasingly complex and integrated systems, and the push for Performance Based Contracting combine to challenge the existing design and sustainment methodologies for defence systems and equipment.
MADe offers an integrated engineering capability that captures and analyses the technical data that is used to support key defence activities including system design, system acquisition, continuous improvement and life extension for air, land or naval systems.
An increasing number of marine renewable energy (MRE) systems are reaching the stage where a working prototype must be demonstrated in operation in order to progress to the next stage of commercial projects. This stage is often referred to as ‘valley of death’ where device developers face the challenge of raising capital needed to demonstrate the prototype. The dilemma is that investors understandably demand a proven track record and demonstrated reliability in order to provide capital. One way to resolve this dilemma is specific component reliability testing that not only satisfies investor expectations but holds the potential to improve and de-risk components for MRE.
Here MADe ensure the product is reliable, safe and cost effective. MADe can be effectively applied to the requirements of a variety of challenges in the marine sector
The operational, financial and environmental risks of system failure; a highly regulated industry and harsh operating conditions offer specific challenges for the systems that are used in the Oil & Gas sector.
MADe is a technology solution that provides the engineering capability to effectively model and analyse the necessary information from a system design to optimise the design process, commissioning and operations of oil and gas platforms.
Importantly, MADe can be effectively applied to meet the requirements of a variety of challenges in the Oil and Gas sector, ranging from unmanned / remote platforms to efficient dispatch regimes and highly iterant and transitional workforces.
The strength of each individual component can determine the product’s performance lifecycle, and, when designed improperly, can potentially cause failure. That is especially true for tractors and other agricultural equipment, which are used in rough terrain and under tough conditions. Immense forces are created when such heavy equipment is in operation. The machinery must also be strong and reliable enough to endure additional loads resulting from a mistake on the part of the operator. Those loads can cause the tractors to operate outside of their normal operating conditions. Accounting for such loading and designing a safe and reliable machine is the task of the engineer—and here’s how this task can be made easier.
The medical industry is one of the fastest growing segments of the world economy, so it is important to the complexity and increased use of medical equipment in non-hospital environments has made the need for safe, reliable products imperative.
