Solutions
Enabling and empowering effective asset structural maintenance management
Overview
WQMS provides a suite of solutions we call the "AICARM Framework" that empowers and enables asset owners to significantly reduce repair welding maintenance costs, extend viable structural life and reduce unplanned downtime. Use the estimator tool below to explore some scenarios regarding just how much your site could save in terms of % of current maintenance costs.
AICARM Framework Benefits Calculator
NOTE: All information is anonymous - feel free to run as many scenarios as you want.
Full information regarding how the assumptions and calculations used for this estimator are provided in this document
Explore the Solutions
PROBLEM
NDT just uses crack visible crack length.
This doesn't provide any data about the nature, depth, material thickness or location of cracking.
Therefore, it is impossible to properly manage risk, set standardised condition severity thresholds, or do detailed repair planning
Informative structural cracking inspection data nomenclature for risk and repair management
SOLUTION
The CDS is a simple yet powerful crack data nomenclature system that provides all of the necessary information for risk and repair management.
Using the CDS it is a relatively simple matter to set standardised conditions severity thresholds that can be used for TARP based asset management.
The CDS is open-source and easy for everyone to understand and use.
PROBLEM
Welders are not trained in maintenance welding, and there can be huge variation in welder knowledge, skill and proficiency.
Simply using welder qualifications is not an effective solution, as these are also based on fabrication - not typical crack repair scenarios.
It is impossible to get effective crack repair outcomes without competent tradesman.
It has been impossible for asset managers to set appropriate Training Needs Analysis requirements for welders which deliver effective repairs, as well as meeting WHS requirements for competent workers.
SOLUTION
The Mining Welder Competency is an industry based micro-credential for training, upskilling and assessing welders for heavy maintenance welding in the resources sector. It ensures welders have the necessary knowledge and skills to carry out effective weld repairs of cracking, and benchmarks their competency at one of 3 levels based on typical crack repair scenarios.
Repair-based welder competency is essential to have confidence in achieving effective repair outcomes.
The Mining Welder Competency is designed to be used by asset managers for site induction and access requirements.
PROBLEM
Welding is too technical and complicated
How do you know what what welding procedure and parameters to use for each crack repair?
Which welder is qualified to follow the procedure
How do you manage quality when there is no welding supervisor available?
How do we apply AS/NZS 1554 for crack repairs?
We can't get a welding procedure from the OEM and don't know what the materials are.
Simplified Welding Management
Simple, practical, functional welding management
SOLUTION
WQMS used a first principles approach based on metallurgical and welding expertise to create a simple, practical and functional basis for mine site maintenance personnel to manage welding
There are 3 broad groups of steel used - structural steel, weldable castings, and high strength steel. Each of these has a simple "Working Temperature" range required - no calculations based on thickness.
WPS's aren't needed if the welder is competent and can dial in the welding parameters, and manage the working temperature
Repair Scenarios provide a simple means to build the required methodology for most crack repairs
PROBLEM
The core problem is that structural cracking of Tier 1 and Tier 2 assets is generally quite poorly managed.
Ad-hoc, unstructured risk management driving maintenance strategies, and ineffective repairs lead to
1. Snowballing crack repairs cause higher maintenance costs and labour shortage issues
2. Increase downtime for routine maintenance, as well as breakdowns
3. Reduced viable structural life, leading to massive costs for early replacement or extensive refurbishment.
Unfortunately, mine sites do not have the tools, systems or trained personnel to do anythign about this. Plus there are deep problems with a lack of welder proficiency to do effective repairs.
It's just too hard to do anything about.... Until now.
Total Crack Repair Management
The holistic structural crack and weld repair management framework for any mine site
SOLUTION
Fundamentally the AICARM Framework improves structural maintenance outcomes to
1. Reduce Maintenance Costs
2. Improve Reliability
3. Extend Viable Asset Structural Life
It is not software with a subscription. The AICARM Framework is a business improvement tool that provide a simple structure and process for a mine to manage and achieve effective crack repairs. It is designed to integrate with the maintenance systems and operations at any site - it is built on People, Paper, Process.
Using the AICARM Framework, a site can easily save more than 2% of total maintenance budget!