SDC Torsion Design

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SIMMS

SIMMS is a proprietary Structural Inspection and Maintenance Management System written to help our steel mill clients manage their building and equipment infrastructure.  SIMMS is a compilation of program modules written in Microsoft Access VBA that manages data linked together from many satellite Access databases.  SIMMS maintains the inspection data, processes the transition inspection reports, post process the inspection data for historical reports or executive summaries, and can output data streams for creating Work Orders in the plant's CMMS System.

Equipment Lists and Reports

  • Equipment ID
    Normally the plant defined cost control code is used to identify a building or piece of equipment in each plant or enterprise.  SIMMS is facilitated to set up a unique text based 5-level identification code that can map seamlessly with the plant defined cost control coding strategy for equipment of various classes or subclasses.
  • Inspection Reports
    Each inspection report ID that has been performed using SIMMS is listed in the Equipment List.  Since OSHA requires annual inspections of cranes, all of the previous inspection reports for a building or piece of equipment can easily be found for audit purposes.
  • Inspection Schedule
    Both the "Date Last Inspected" and the "Date Due for Next Inspection" are shown on the Equipment List.  SIMMS will automatically calculate the due date for the next inspection in accordance with the clients inspection frequency schedule.  Alternately, SDC can develop a special "condition based" inspection schedule.
  • Structural Rating
    Upon completion of each inspection, a Licensed Professional or Structural Engineer will assign a structural rating (Good, Fair, Poor) to each structure based on an evaluation of the inspection results.  The Structural Rating of each piece of equipment is shown on the Equipment List.  The Structural Rating is retained by SIMMS for management purposes. 

Inspection Frequency Strategy

  • Inspection Matrix
    SIMMS was developed with an inspection matrix that can be customized to meet individual enterprise/plant needs.  The inspection frequency is based on the equipment type and rated condition of the structure after the baseline inspection has been performed.  SIMMS categorizes the equipment types as Moving Equipment, Support to Moving Equipment, and Stationary Structures.
  • Critical Equipment
    Some equipment can be categorized as critical to plant operations or client designation to each structure and set the inspection frequency as deemed necessary by Engineering.
  • Federal Regulations
    The Code of Federal Regulations 1910 29CFR Part 1910 requires that cranes be inspected annually.  The inspection matrix can be set to meet Federal Regulations.

Inspection Standards

  • Deficiency Codes
    SIMMS was developed after performing structural inspections in steel mills for many years.  Standard deficiency codes have been developed for each equipment class and subclass.  For example, a 12" crack in a crane girder web fillet weld would be noted as c-gw-w-l-12. Two (2) sheared anchor bolts would be noted as s-a-b-c-2.  Locating the crack for the repair crew can be difficult.  The use of standard deficiency codes eliminates confusion, standardizes terminology, and allows the inspection data to be post processed for management reports or parsed for uploading into the plant's CMMS System.
  • Deficiency Location
    Many times Maintenance personnel have a difficult time to locate a deficiency noted in a report.  SIMMS can locate a deficiency by using five (5) different fields to define the building column lines or major equipment components such as a trolley or end truck.
  • Repair Priority
    A repair priority, rated on a scale of 1-5, is then given to each deficient item.  Items assigned with a Priority 1 require immediate corrective action while level Priority 5 is used to define items that are noted For Record Only.  Most steel mills repair the Priority 1's along with the Priority 2's that are noted for repair As Soon As Possible.
  • Safety
    Inspecting cranes and crane runways is dangerous.  SIMMS has been programmed to incorporate SDC's safety program.  Safety Inspection Checklists can be printed out with the inspection data forms for each inspection team.  SIMMS can also keep track of inspector training records and records for the inspection of safety equipment.  SIMMS can cross check the inspector's safety certifications with the unique inspection requirements for each structure.

Inspection Reports

  • Standard Inspection Report
    A standard report includes an Introduction which serves as our inspection specification.  The General Findings is a narrative that summarizes the detailed inspection results and sorts the deficiencies by repair priority and location.  The complete list of detailed inspection deficiencies is provided in the Specific Findings in a standard SIMMS report.  The deficiencies are listed by location so they can be easily found by the repair contractor.  A standard repair recommendation is provided for each structural deficiency.  A Repair Strategy may be included in a standard report if necessary to address the root cause of a structural problem.   A Deficiency Location Plan can also be provided in the report.  The location sketch can be scanned into SIMMS or a computer generated plan can be automatically generated by SIMMS for a crane or crane runway.
  • Repair Cost Estimates
    Based on our experience with standard repairs, SIMMS can provide a repair cost estimate.  For example, we know that it takes an ironworker crew 1 hour to make a 1" long full penetration weld repair.  The SIMMS cost estimating module can provide an order of magnitude for making structural repairs for each repair priority code.  Reports can be generated that summarize the total number of deficiencies and associated repair costs for various groups of equipment.

Management Reports

  • Executive Summary Report
    Plants or Enterprises with large numbers of structures need to be efficiently managed.  Capital expenditures for building rehabilitation need to be justified and included in the capital plan.  SIMMS can provide executive management with the information needed to justify the expenditures by summarizing the General Findings for the critical structures or structures rated in poor structural condition in a single document.
  • Condition Based Repair Plans
    Since SIMMS is a database application, it can sort the inspection data by any means that can be imagined.  SDC has provided many of our steel mill clients with repair plans that are specific to a particular need.  We have provided plans for only the high priority repairs for equipment rated in poor, fair, or good structural condition.  We have also sorted the data by deficiency code.  One client wanted to subcontract all of the full penetration weld repairs to certified welders.  SIMMS generated a report for the full penetration welds for all of the EOT cranes and crane runways in the plant on a priority basis.
  • Historical Record Reports
    All inspection findings for each piece of equipment are stored permanently in the SIMMS database.  After a baseline inspection has been completed, the data is retrieved for subsequent inspections.  SDC back checks the inspection findings from the historical records when performing the next regularly scheduled or reinspection.  SDC notes whether the deficiencies noted during the previous inspection were repaired, remained unchanged, or continued to deteriorate.  SIMMS has the capability to link each of the inspection findings to provide a historical record of each deficiency. Historical information is valuable in monitoring the condition of a building or piece of equipment and making critical repair/replace decisions.  Some of our steel mill customers use this feature to help justify capital expenditures.
  • Equipment Deficiency Status Reports
    It is important to know how the structural deficiencies for a piece of equipment have changed since the previous inspection(s).  SIMMS can provide a detailed summary that shows which deficiencies are new, have experienced further deterioration, have remain unchanged or have been repaired.  Other deficiencies may need to be reinspected or need to be closed out after repair.  SDC notes some inspection items For Information Only to document a non-structural condition.

Plant CMMS Systems

  • Work Order Generation
    SIMMS can automatically generate data streams in any customized format for creating work orders or any other purposes in the plant or Enterprise CMMS System. To integrate the SIMMS and the CMMS system, SDC will develop a custom scheme in Microsoft Access to map the inspection data to be uploaded. The mapping data record fields will be formatted in accordance with the requirements approved by the plant maintenance and IT Departments. SDC will supply an upload text file ready for parsing into the CMMS data fields.
  • 3rd Party Inspection Report Data Conversion
    Most inspection reports are written in a narrative style, text based format using a word processor.  SDC has taken our clients old reports and converted them into SIMMS to take advantage or our inspection/deficiency standards and database capabilities for integration into their CMMS System.