Under Plan Pelican Relken is working with KPMG to reform the maintenance paradigm across army aviation to create a more efficient and effective capability. Relken's expertise in Maintenance Policy Management and data analysis have been critical to the identification and remediation of the way Maintenance Policy is managed across Army's helicopter fleets. As part of the Overall program, Relken developed a Maintenance Liability Calculator in MATLAB which models the fleet profile to understand the cost (in terms of resources) of the current maintenance program and predict how changes to support arrangements will affect the resources required. Relken is developing the strategic policy to manage maintenance policy across the Army Aviation platforms.
GLENCORE LONGWALL PERFORMANCE IMPROVEMENT PROGRAM
JoyGlobal & Glencore
Relken is working with JoyGlobal and Glencore to increase the productivity of the Underground Longwall mining system in operation in QLD. Relken’s reliability engineering expertise and exclusive root cause analysis process are helping JoyGlobal and Glencore to achieve a meaningful increase in the coal production from this low seam Longwall operation.
UNDERGROUND COAL ROOT CAUSE ANALYSIS
JoyGlobal & Illawarra Coal
Relken is facilitating a root cause analysis program to overcome some a technical constraints at Illawarra Coal’s underground coal operation in NSW. Relken has been able to coordinate the mine operators and equipment OEM to work towards a common goal in improving the conditions and production on this longwall operation.
Electronic System Division
Defence’s Satellite Communication System Program Office have engaged Relken through KPMG to provide specialist input and review to the ILS and LSA programs for the development of a new Satellite Ground Station in Western Australia and an upgrade to the Ground station at HMAS Harman in Canberra. The insights provided by Relken have allowed the Commonwealth and Prime contractor BAE to understand what is needed to develop an efficient and effective support system for this critical communication capability and has identified improvements in spares modelling and supportability analysis of the current system. The contract is underpinned by a performance based payment structure and Relken has also been able to provide guidance on potential mechanisms for estimating the risk of meeting these contracted performance measures.
LAND 121 BRIDGE BOAT INTERFACE ILS PROGRAM
Relken has been engaged by GHD to manage the ILS program for the Bridge Boat Interface aspects of Land 121 on behalf of a key equipment supplier. Relken’s experience in development, delivery and review and of ILS and LSA reports has been critical to ensuring the development of an efficient support system and Contracted Data Requirements that are compliant with s Data Item Descriptions (DIDs) outlined by the Commonwealth.
ENGINEERING ANALYSIS BUREAU
Royal Australian Navy
This Royal Australian Navy engaged Relken to design their new Engineering analysis Bureau established in response to recent reviews into Naval Engineering (e.g. Rizzo and Strategic Review of Naval engineering). The experience of Relken’s staff in leading Reliability Engineering Centres of Excellence across Air Force, Army and Navy and our understanding of military logistics information systems means that Relken understands Navy’ objectives in developing an engineering analysis capability and what needs to be done to establish the organisation people, process and data to achieve them.
WARRAGAMBA DAM FAULT TREE ANALYSIS
Sydney Catchment Authority
Relken incorporated system upgrades into the Warragamba Dam fault tree in order to prioritise and recommend additional reliability improvements. Relken was selected because of its Masters qualified discipline specialists who understand both the theory and the practical considerations of reliability modelling. The Sydney Catchment Authority placed significant confidence in the products and advice provided by Relken, which is especially important given the role this analysis played in assessing public safety.
OVERHAUL IMPROVEMENT STRATEGY
Relken was sought as independent program facilitators by JoyGlobal and Glencore to Lean their overhaul framework and planning. Relken was able to assist two joint venture companies define shared objectives, processes and approaches for the development and execution of an Overhaul Performance Improvement Program.
RISK ASSESSMENT - GAS POWER STATION
Energy Developments Ltd
EDL asked Relken to facilitate an independent risk-based design review of a proposed methane generation facility. Relken engaged design stakeholders across multiple organisations to deliver a robust risk assessment of design issues.
RAM TRAINING NEEDS ANALYSIS
Australian Defence Organisation
Relken Engineering was engaged through JPG Partners and Defence Reliability Working Group to conduct a Training Needs Analysis (TNA) of Reliability, Availability and Maintainability (RAM) skills, knowledge and training used across the Australian Defence Organisation. Relken successfully defined specific training needs across a diverse stakeholder group to deliver targeted training requirements and training solution options.
COMMON CAUSE FAILURES IN THE NUCLEAR INDUSTRY
U.S. Nuclear Regulatory Commission
On behalf of the United States Nuclear Regulatory Commission (NRC) Relken reviewed industry feedback on range of proposed NRC regulations. Relken's status as a trusted advisor to the NRC enabled us to shape and consider industry responses throughout a period of open stakeholder consultation.
LIFE OF TYPE REVIEW: SPECIAL FORCES RIGID HULL INFLATABLE BOAT
Hydrographic Systems Program Office, Maritime Systems Division - CASG
Relken successfully completed the Life of Type Review for the Army's fleet of 11m Special Forces Rigid Hull Inflatable Boat. This activity utilised risk-based approach to determine the system's ability to meet its capability requirements through to the stated Life of Type (LOT). It involved engagement with major Defence stakeholders across Services and functions. Relken combined detailed qualitative and quantitative analysis of maintenance and supply data to provide a robust risk assessment of supportability issues.
MINE HUNTER FLEET RELIABILITY CENTRED MAINTENANCE ANALYSIS
Capability Acquisition and Sustainment Group-Maritime Systems Division-Mine Warfare and Clearance Diving Systems Program Office
MCDSPO is responsible for the sustainment of the Huon-class fleet of Mine Hunter vessels operated by the Royal Australian Navy (RAN). Faced with ongoing reliability and life cycle cost issues with some key shipboard systems, MCDSPO undertook a trial program to implement an optimised maintenance regime for the Huon’s Auxiliary Propulsion Units and Sonar Main Winch based on RCM principles. Relken was appointed to facilitate multiple RCM workshops, analyse historical failure data and develop Reliability Block Diagrams for the nominated sub-systems, while closely engaging with MCDSPO, RAN and Original Equipment Manufacturers. The maintenance regime developed from the RCM process identified opportunities to save approximately $9 million in labour costs for the in-service fleet over a 12 year maintenance cycle, whilst reducing the probability of maintenance-induced failures through maximised usage of condition-based maintenance techniques.
AFC FLIGHT BAR & CHAIN FAILURE - ROOT CAUSE ANALYSIS
Relken was asked to conduct a Root Cause Analysis (RCA) investigation into an underground mine producing metallurgical coking coal in response to an increase in Longwall downtime. During the investigation, Relken discovered unexpected failure modes and an unusually high number of AFC flight bar and chain failures. In conjunction with Joy Global and the equipment operator, Relken executed an RCA to identify the most likely causes and then establish remedial actions. Relken facilitated multiple RCA workshops, analysed historical failure data and gathered evidence to determine causal factors and the root cause. The RCA yielded a number of preventative and corrective actions, which were immediately implemented to reduce the impact of the failure causes or to design out the cause effects.
Army Land Vehicles PLAN CENTAUR – Maintenance Reform
Plan CENTAUR is an Army led project to reform maintenance practices in order to meet the requirements of a new Concept of Operations for Australian Army vehicle assets.
Relken’s expertise in data analysis and our understanding of Defence sustainment systems enabled us to analyse Armoured Fighting Vehicle (AFV) Fleet maintenance performance. In this phase, Relken identified the objectives of maintenance, taking into consideration Army’s unique requirements, to then baseline current performance from existing maintenance data. Relken completed a deep dive into 3 years of maintenance data across the AFV fleets to determine the nature and scope of improvements in maintenance processes and performance. The team used stakeholder interviews to validate and confirm data insights that correlated with the ‘lived experience’. Relken then outlined the key data fields that illustrate maintenance performance and provided an assessment of available data quality.
Relken’s support to the current phase of the reform program culminated in a U-Collaborate Event, which provided a coherent status of current maintenance performance. Historically, this performance data had been considered unavailable or too challenging to interpret. Relken substantiated and quantified anecdotal issues to inform specific reform topics. Furthermore, the analysis of existing data revealed a series of previously unidentified contributory factors.
PATROL BOAT FLEET DATA REPORTING, ANALYSIS AND CORRECTIVE ACTION SYSTEM
Patrol Boat Systems Program Office, Maritime Systems Division – CASG
The Armidale Class Patrol Boat (ACPB) fleet provides the Navy’s principal contribution to the task of national maritime patrol - encompassing fisheries protection, immigration, customs and law enforcement operations. As part of a fleet-wide remediation program, Relken was tasked with the design and development of a Data Reporting, Analysis and Corrective Action System (DRACAS) to integrate with the Patrol Boat System Program Office (PBSPO) engineering change and configuration control processes.
Over a 12 month period, Relken developed and delivered enhanced processes, training material and bespoke tools and frameworks to successfully implement the DRACAS. The Relken team minimised the impact to daily work activities by leveraging and enhancing existing PBSPO processes and corporate knowledge. Relken also performed an asset health assessment via the DRACAS to demonstrate system validity, identify key systems for consideration during the ongoing remediation program, and propose corrective actions.
ASC ISO55000 ASSET MANAGEMENT AUDIT
ASC-Adelaide, South Australia
ASC was the subject of the external Coles Review, which reported Asset Management as part of its analysis into enterprise improvement areas. At the request of ASC, Relken performed an audit of ASC’s submarine business unit against the requirements of the ISO55000-Asset Management suite of standards to determine areas of compliance and opportunities for improvement. Relken conducted a thorough desktop review of the corporation’s Asset Management System using a bespoke assessment process, validated during interviews with key Asset Management personnel. Relken’s report identified improvement actions that enabled ASC to alter existing Asset Management practices to achieve alignment with the ISO55000 standard. Relken also identified compliance gaps, which was addressed by providing a comprehensive compliance roadmap and delivering prioritised closure actions to enable greater sustainment efficiencies for the Collins Class submarine fleet. ASC has since invited Relken to return on an ongoing basis to support Strategic Asset Management activities, including enterprise Asset Management Planning and the design of the organisation’s Asset Management framework.
UNDERGROUND COAL MINE LONGWALL AND DEVELOPMENT EQUIPMENT DOWNTIME ANALYSIS
Glencore - Oaky Creek North Underground Coal Mine
Oaky Creek North is an underground coal mine that produces two premium quality, medium volatile coking coals. After experiencing performance below that projected Relken was engaged to analyse the equipment’s previous downtime data in order to identify performance improvements.
Relken built a series of dashboards that was used within workshops to identify specific issues and improvement actions. The analysis resulted in the identification of 26 corrective actions which were estimated to save a total 19hrs of Longwall downtime per week equating to approximately $2.85M of increased production.
Relken developed business cases for each corrective action using the data analysis to estimate the resulting performance improvement. A dashboard was developed for each corrective action so progress of that correct action could be measured weekly using data from the current longwall performance.
P-8A SAFETY CRITICAL – INDEPENDENT MAINTENANCE INSPECTIONS
Capability Acquisition and Sustainment Group-Aerospace Systems Division-Project AIR7000 PH2B Intelligence, Surveillance and Reconnaissance Program Office
Project AIR7000 Phase 2B Intelligence, Surveillance and Reconnaissance Program Office is responsible for the acquisition and introduction into service of the new Manned Maritime Patrol and Response Aircraft (MPRA), consisting of twelve P-8A Poseidon’s to replace the AP-3C Orion fleet. The Project had previously identified systems where the loss of function would have Safety or Safety-Hidden consequences in accordance with the Reliability Centred Maintenance and Maintenance Steering Group-3 (MSG-3) process. Relken was appointed to develop evidence in the form of Independent Maintenance Inspection (IMI) engineering assessments to demonstrate that the Certification and Service Release aspects of the aircraft have been adequately met. Relken developed a methodology that assessed each maintenance task on the Safety Critical Systems/Items list for existing barriers that prevented/detected the occurrence of credible maintenance errors. This process involved:
- Confirming that the task met the Independent Maintenance Inspection criteria
- Identifying all credible maintenance errors that would lead to the loss of Safety Critical Systems/Item function
- Identifying any design barriers that would prevent or detect the maintenance error
- Identifying any test barriers that would prevent or detect the maintenance error
- Developing an Independent Maintenance Inspection that is;
- A discrete conformance activity
- Consistent across equivalent maintenance tasks
The assessment process was recorded with all IMI recommendations fully documented. In total:
- 260 assessments were completed over eight weeks containing 4,421 maintenance tasks.
- 1,483 Independent Maintenance Inspection candidates were identified.
- 104 Independent Maintenance Inspections were recommended, and accepted by the Design Acceptance Representative as providing an efficient and compliant set of IMIs meeting an acceptable level of safety for the platform’s introduction to service
HMAS CHOULES RELIABILITY CENTRED MAINTENANCE ANALYSIS
Atlantic & Peninsula Australia
Atlantic & Peninsula Australia (A&P) manage the In-Service Support and Sustainment Contract (ISSC) for HMAS Choules as a supplier to the Landing Helicopter Dock System Program Office (LHDSPO). HMAS Choules experienced two major operational defects, requiring detailed incident analysis. Relken was engaged to facilitate Reliability Centred Maintenance (RCM) workshops and consequentially delivered a revised maintenance regime, operating procedures and system design changes to significantly reduce the risk of incident recurrence. Relken’s outputs were aligned with A&P’s Life Cycle Cost (LCC) report, which resulted in implementation approval for the remediation activities.