DORA Software

DORA = Dynamic Operational Reliability Analyser, a software tool for maintenance management professionals.

Professional maintenance is not only focused on machines, but on the failure behavior of the entire production chain. Maintenance that is not only technical, but maintains all factors that affect returns.

Companies that use DORA software do this on

  • improve line returns
  • provide insight into the costs of downtime, maintenance and process disruption
  • Maintain not only the machines but also the failure behaviour.
  • improve the impact on safety, health and the environment
  • improve the quality of products and services
  • develop maintenance concepts / plans and programmes
  • to create knowledge bases about all the effects on returns (failure behaviour)
  • make maintenance analyses
  • improve the interaction between man and machine
  • improve the effectiveness of the maintenance management system

DORA is developed by a team of reliability specialists from sixteen companies, who are responsible for production, maintenance and reliability on a daily basis. They work with CMMS’s on a daily basis. They carry out their own maintenance plans and those of their suppliers. However, they still suffer too much from unacceptable failures, too much downtime and too high costs, as well as unacceptable effects on quality, safety, health and the environment. These sixteen companies had one thing in common: The existing maintenance plans did not maintain the ACTUAL fault behaviour.

Maintenance influences failure behaviour.

We do report malfunctions, but do not describe their behaviour. Linking malfunctions to functional locations only makes sense if the malfunction is described at the right level. More than 70% of the process disruptions are caused by people. If the electric motor burns out as a result, why do we link the cost of repair to the electric motor and not to its operation? The only maintenance task that can prevent this is to teach the operator how to operate. If more than 70% of the failures are caused by people, what percentage of your maintenance plan does your people maintain? We also need to maintain people, as well as procedures, safety, health and the environment. Maintenance should focus on ALL effects that affect returns.

When maintenance remains a technical responsibility, progress is limited.

Anyone who has an effect on returns must be involved in maintenance. Faults are groups of faults. Malfunctions are malfunctions including the underlying rescues. And these types of faults describe the behaviour of faults. We describe the failure behaviour in an FMEA or FMECA. For the development of maintenance concepts, we record failure behaviour in Process FMEAs and Object FME(C)As, depending on whether we are looking for solutions for high-middle-low critical systems. The maintenance concept is developed with the aid of a decision making strategy. This still needs to be nested into a maintenance plan in order to optimise the maintenance programme in the CMMS. As a result, the CMMS is much more effective and costs are distributed in such a way that maintenance can also be improved as a result.

Maintenance plans are never finished.

Almost all production processes have to do with dynamic failure behaviour. If we maintain this with static maintenance plans, we do not cover this failure behaviour properly. This causes unplanned downtime, and we suffer from reduced line yields and effects on costs, quality, etc. Dynamic production processes must be maintained with dynamic maintenance plans. Maintenance plans must also be maintained.
Suppliers do not have to make maintenance plans.
Suppliers do not know the level of knowledge of the operators. Neither the budget nor the quality of the raw materials. Not the procedures and do not determine the quality level that customers need. There are so many factors that affect failure behavior, that only operational departments such as raw materials, production, technical service, quality control, administration and logistics have knowledge of failure behavior. The knowledge of the supplier is limited. He only knows the machine that only has a 30% influence on the efficiency. At most, a supplier can make a proposal that has to be adapted by the future owner. If modifications or customer-specific options are implemented in order to prevent specific types of malfunctions, they no longer need to be maintained. Maintenance plans are always tailor-made.
What suppliers can do, however, is to provide a good overview of all possible types of malfunctions and to make a start on which maintenance concept should be used to do something about it. It still depends on whether the customer works 24×7 or 8×5 for example. If the maintenance need (read fault behaviour) is different, the maintenance plan will be different.

DORA Software

DORA-Software facilitates users in all these activities. Most companies already do some form of asset management. By starting Reliability Management on time, the next step is taken and continuous improvement is accelerated.
DORA Software facilitates these improvement processes. It contains methods to work in a structured way. The complete administration required to make maintenance plans is recorded in DORA Software.
DORA can be used by people who make maintenance plans. The size of the company is not important. How far the company is with maintenance either. It even has great advantages to start early and thus prevent incorrect information from being recorded that needs to be optimized later on.

The following packages are available:
– Single User QM
– Single User Pro
– Multi User
– Enterprise
DORA Software helps users to do what is necessary to manage disruption behaviour. Some of the functionalities are:
1. Making Criticality Analyses
2. Creating FMEA or FMECAs
3. Create new maintenance concepts with three methods for high-middle-low critical systems
1. Reliability Centred Maitenance
2. Object Driven Maintenance
3. Quick Maintenance
4. Optimise existing maintenance plans
5. Reporting malfunctions and solutions
6. Linking the failure behaviour in the FME(C)A to PLC, SCADA, Internet4, Start/Stop signals, Big Data, … to keep FME(C)A’s up to date
7. Generating OEE reports based on start/stop signals
8. Show dynamic paretos for quick analysis.

On all articles can be found and information about all training courses is available.