Background :
Background Reliability Centered Maintenance (RCM) is a proven, logical, approach that helps companies improve equipment reliability.
Developed by the US Aviation Industry in the 1960’s
Has successfully been implemented in many other industries.
Reliability Centered Maintenance (RCM) :
Reliability Centered Maintenance (RCM) What a system is supposed to do? (Function)
How can it fail to do that? (Functional Failure)
What can cause it to fail? (Failure Modes)
What happens when it does fail? (Effects)
What can be down to predict or prevent the failure from happening? (Maintenance Plan)
Why Now? :
Why Now? The increasing drive towards Lean Manufacturing, 5s etc has resulted in less equipment redundancy and ever increasing equipment uptime (reliability) expectations.
Benefits :
Benefits Increases Maintenance Effectiveness
Ensuring equipment is neither over or under maintained.
doing the right kind of maintenance.
getting the right balance between Planned and Un-Planned maintenance.
Increases Maintenance Efficiency
Compares the cost of Running Equipment to Failure against the cost of performing Preventative Maintenance.
performing maintenance at the right frequency.
Maintenance Tech Benefits :
Maintenance Tech Benefits Significant Up-Skilling Opportunity;
gain a detailed understanding of how the process is supposed to operate. (Cross Training)
become as proficient as a vendor in the maintenance of critical equipment.
maintenance departments are being forced to reduce costs by eliminating their dependence on outside vendors for routine equipment servicing.
learn about and get training in the latest Predictive Maintenance PdM techniques and technologies.
Vibration analysis
Thermo graphics
Oil analysis
Acoustic leak detection
Motor monitoring systems
learn how to identify and justify equipment design changes.
Key Performance Indicators (KPIs)
PM content, duration and spares requirements are optimized
less risk of PMs becoming overdue; having to use up more annualised hours or having to work overtime to clear the backlog.
Operator Benefits :
Operator Benefits Up-Skilling Opportunity;
gain a detailed understanding of how equipment can fail and it’s effect on process uptime /reliability. (Cross Training)
identify non technical maintenance tasks that can best be performed by operators. (Owner Asset Care – visual inspections)
learn how to identify and justify equipment design changes.