RELIABILITY-CENTERED MAINTENANCE (RCM)

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RELIABILITY-CENTERED MAINTENANCE (RCM) : 

RELIABILITY-CENTERED MAINTENANCE (RCM) RCM IS A SYSTEMATIC CONSIDERATION OF SYSTEM FUNCTIONS, THE WAY FUNCTIONS CAN FAIL, & A PRIORITY-BASED CONSIDERATION OF SAFETY AND ECONOMICS THAT IDENTIFIES APPLICABLE & EFFECTIVE PM TASKS.

RELIABILITY-CENTERED MAINTENANCE (RCM) : 

RELIABILITY-CENTERED MAINTENANCE (RCM) RELIABILITY-CENTERED MAINTENANCE (RCM) IS THE PROCESS OF DETERMINING THE MOST EFFECTIVE MAINTENANCEAPPROACH. RCM WAS FIRST APPLIED ON A LARGE SCALE TO DEVELOP THE MAINTENANCE PROGRAM OF THE BOEING 747. KNOWN AS MSG-3 IN THE AEROSPACE INDUSTRY.

RELIABILITY-CENTERED MAINTENANCE (RCM) : 

RELIABILITY-CENTERED MAINTENANCE (RCM) RCM IS A TECHNIQUE FOR DEVELOPING A PM PROGRAM. IT IS BASED ON THE ASSUMPTION THAT THE INHERENT RELIABILITY OF THE EQUIPMENT IS A FUNCTION OF THE DESIGN AND THE BUILD IN QUALITY. AN EFFECTIVE PM PROGRAM WILL ENSURE THAT THE INHERENT RELIABILITY IS REALISED.

MAIN OBJECTIVE OF RCM : 

MAIN OBJECTIVE OF RCM TO REDUCE THE MAINTENANCE COST, BY FOCUSING ON THE MOST IMPORTANT FUNCTIONS OF THE SYSTEMS, AND AVOIDING OR REMOVING MAINTENANCE ACTIONS THAT ARE NOT STRICTLY NECESSARY.

RCM HISTORY : 

RCM HISTORY ORIGINATED IN THE AIRLINE INDUSTRY IN THE 1960’S. BY THE LATE 1950’S, THECOST OF MAINTENANCE ACTIVITIES IN THE AIRLINE INDUSTRY HAD BECOME HIGH ENOUGH TO WARRANT A SPECIALINVESTIGATION INTO THE EFFECTIVENESS OF THOSE ACTIVITIES. ACCORDINGLY, IN 1960, A TASK FORCE WAS FORMED.

RELIABILITY CENTERED MAINTENANCE HISTORY : 

RELIABILITY CENTERED MAINTENANCE HISTORY CONSISTING OF REPRESENTATIVES OF BOTH THE AIRLINES AND THE FEDERAL AVAITION ADMINISTRATION (FAA-US) TO INVESTIGATE THE CAPABILITIES OFPREVENTIVE MAINTENANCE. THE ESTABLISHMENT OF THIS TASK FORCE SUBSEQUENTLY LED TO THE DEVELOPMENT OF A SERIES OF GUIDELINES FOR AIRLINES AND AIRCRAFT MANUFACTURERS TO USE, WHEN ESTABLISHING MAINTENANCESCHEDULES FOR THEIR AIRCRAFT.

RCM PHILOSOPHY EMPLOYS THESE TECHNIQUES : 

RCM PHILOSOPHY EMPLOYS THESE TECHNIQUES PREVENTIVE MAINTENANCE (PM) PREDICTIVE MAINTENANCE (PDM) REAL-TIME MONITORING (RTM1) RUN-TO-FAILURE (RTF - ALSO CALLED REACTIVE MAINTENANCE) PROACTIVE MAINTENANCE

THE GOAL OF THE RCM PHILOSOPHY : 

THE GOAL OF THE RCM PHILOSOPHY TO PROVIDE THE STATED FUNCTION OF THE FACILITY, WITH THE REQUIRED RELIABILITY ANDAVAILABILITY AT THE LOWEST COST. RCM REQUIRES THAT MAINTENANCE DECISIONS BE BASED ON MAINTENANCEREQUIREMENTS SUPPORTED BY SOUND TECHNICAL AND ECONOMIC JUSTIFICATION.

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM IS FUNCTION ORIENTED IT SEEKS TO PRESERVE SYSTEM OR EQUIPMENT FUNCTION, NOT JUSTOPERABILITY FOR OPERABILITY'S SAKE. REDUNDANCY OF FUNCTION, THROUGH MULTIPLE EQUIPMENT,IMPROVES FUNCTIONAL RELIABILITY, BUT INCREASES LIFE CYCLE COST IN TERMS OF PROCUREMENT ANDOPERATING COSTS.

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM IS SYSTEM FOCUSED IT IS MORE CONCERNED WITH MAINTAINING SYSTEM FUNCTION THANINDIVIDUAL COMPONENT FUNCTION. RCM IS DRIVEN BY SAFETY AND ECONOMICS SAFETY MUST BE ENSURED AT ANY COST; THEREAFTER, COST-EFFECTIVENESS BECOMES THE CRITERION.

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM IS RELIABILITY CENTERED IT TREATS FAILURE STATISTICS IN AN ACTUARIAL MANNER. THE RELATIONSHIP BETWEEN OPERATING AGE AND THE FAILURES EXPERIENCED IS IMPORTANT. RCM IS NOT OVERLY CONCERNED WITH SIMPLE FAILURE RATE IT SEEKS TO KNOW THE CONDITIONAL PROBABILITY OF FAILURE AT SPECIFIC AGES (THE PROBABILITY THAT FAILURE WILL OCCUR IN EACH GIVEN OPERATING AGE BRACKET).

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM ACKNOWLEDGES DESIGN LIMITATIONS ITS OBJECTIVE IS TO MAINTAIN THE INHERENT RELIABILITY OF THE EQUIPMENT DESIGN, RECOGNIZING THAT CHANGES IN INHERENT RELIABILITY ARE THE PROVINCE OF DESIGN RATHER THAN MAINTENANCE. RCM RECOGNIZES THAT MAINTENANCE FEEDBACK CAN IMPROVE ON THE ORIGINAL DESIGN. RCM RECOGNIZES THAT A DIFFERENCE OFTEN EXISTS BETWEEN THE PERCEIVED DESIGN LIFE AND THE INTRINSIC OR ACTUAL DESIGN LIFE, AND ADDRESSES THIS THROUGH THE AGE EXPLORATION (AE) PROCESS.

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM DEFINES FAILURE AS ANY UNSATISFACTORY CONDITION THEREFORE, FAILURE MAY BE EITHER A LOSS OF FUNCTION (OPERATION CEASES) OR A LOSS OF ACCEPTABLE QUALITY (OPERATION CONTINUES).

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM USES A LOGIC TREE TO SCREEN MAINTENANCE TASKS THIS PROVIDES A CONSISTENT APPROACH TO THE MAINTENANCE OF ALL KINDS OF EQUIPMENT.

RCM LOGIC TREE : 

RCM LOGIC TREE

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM TASKS MUST BE APPLICABLE THE TASKS MUST ADDRESS THE FAILURE MODE AND CONSIDER THE FAILURE MODE CHARACTERISTICS. RCM TASKS MUST BE EFFECTIVE THE TASKS MUST REDUCE THE PROBABILITY OF FAILURE AND BE COST EFFECTIVE.

THREE TYPES OF MAINTENANCE TASKS : 

THREE TYPES OF MAINTENANCE TASKS TIME-DIRECTED (PM) – SCHEDULED WHEN APPROPRIATE. CONDITION-DIRECTED (PDM AND REAL-TIME MONITORING) – PERFORMED WHEN CONDITIONS INDICATE THEY ARE NEEDED. FAILURE FINDING (ONE OF SEVERAL ASPECTS OF PROACTIVE MAINTENANCE) AFTER IT HAS FAILED, INVESTIGATE THE CAUSES OF FAILURES. EQUIPMENT IS RUN-TO-FAILURE. THIS IS ACCEPTABLE FOR SOME SITUATIONS AND SOME TYPES OF EQUIPMENT.

PRIMARY RCM PRINCIPLES : 

PRIMARY RCM PRINCIPLES RCM IS A LIVING SYSTEM IT GATHERS DATA FROM THE RESULTS ACHIEVED AND FEEDS THIS DATA BACK TO IMPROVE DESIGN AND FUTURE MAINTENANCE. THIS FEEDBACK IS AN IMPORTANT PART OF THE PROACTIVE MAINTENANCE ELEMENT OF THE RCM PROGRAM.

RCM ANALYSIS CONSIDERS THE FOLLOWING QUESTIONS : 

RCM ANALYSIS CONSIDERS THE FOLLOWING QUESTIONS WHAT DOES THE SYSTEM OR EQUIPMENT DO? WHAT IS ITS FUNCTION? WHAT FUNCTIONAL FAILURES ARE LIKELY TO OCCUR? WHAT ARE THE LIKELY CONSEQUENCES OF THESE FUNCTIONAL FAILURES? WHAT CAN BE DONE TO REDUCE THE PROBABILITY OF THE FAILURE? IDENTIFY THE ONSET OF FAILURE, OR REDUCE THE CONSEQUENCES OF THE FAILURE?

RCM IS APPLICABLE TO… : 

RCM IS APPLICABLE TO… WHERE LARGE, COMPLEX EQUIPMENT IS USED WHERE EQUIPMENT FAILURES POSE SIGNIFICANT ECONOMIC, SAFETY, OR ENVIRONMENTAL RISKS. AERO / ASTRO INDUSTRIES NAVY UTILITY COMPANIES OFFSHORE INDUSTRY MANUFACTURING PROCESS

BENEFITS OF RCM : 

BENEFITS OF RCM

INSTITUTING AN RCM PROGRAM DEPEND ON… : 

INSTITUTING AN RCM PROGRAM DEPEND ON… NATURE OF THE BUSINESS RISKS POSED BY EQUIPMENT FAILURE STATE OF THE EXISTING MAINTENANCE PROGRAM

TO DEVELOP AN RCM PROGRAM : 

TO DEVELOP AN RCM PROGRAM WHAT ASSETS ARE OWNED & OPERATED BY THE COMPANY? TO WHICH OF THESE SHOULD RCM BE APPLIED? WHAT ARE THE FUNCTIONS & PERFORMANCE EXPECTATIONS OF EACH SELECTED ASSET? IN WHAT WAYS CAN IT FAIL TO PERFORM THESE FUNCTIONS?

TO DEVELOP AN RCM PROGRAM : 

TO DEVELOP AN RCM PROGRAM WHAT CAUSES IT TO FAIL? WHAT ARE THE CONSEQUENCES OF EACH FAILURE? WHAT SHOULD BE DONE TO PREVENT EACH FAILURE? WHAT STEPS SHOULD BE TAKEN IF PREVENTIVE MEASURES CAN’T BE FOUND?

PURPOSE OF THE RCM REVIEW PROCESS : 

PURPOSE OF THE RCM REVIEW PROCESS TO DEFINE THE MAINTENANCE REQUIREMENTS FOR A PHYSICAL ASSET THAT ARE NECESSARY TO MEET THE BUSINESS OBJECTIVES. THE LEVEL OF PERFORMANCE REFLECTS WHAT IS REQUIRED OR WANTED FROM THE ASSET.

MAJOR STEPS IN THE RCM REVIEW PROCESS : 

MAJOR STEPS IN THE RCM REVIEW PROCESS STEP 1 SELECT PLANT AREAS THAT MATTER STEP 2 DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS STEP 3 DETERMINE PLAUSIBLE FUNCTIONAL FAILURES STEP 4 DETERMINE LIKELY FAILURE MODES & THEIR EFFECTS

MAJOR STEPS IN THE RCM REVIEW PROCESS : 

MAJOR STEPS IN THE RCM REVIEW PROCESS STEP 5 SELECT FEASIBLE & EFFECTIVE MAINTENANCE TACTICS STEP 6 IMPLEMENT SELECTED TACTICS STEP 7 OPTIMIZE TACTICS & PROGRAMS

STEP 1 - SELECT PLANT AREAS THAT MATTER : 

STEP 1 - SELECT PLANT AREAS THAT MATTER ESTABLISH A STRUCTURED, COMPREHENSIVE LIST OF ALL PHYSICAL ASSETS OWNED OR USED THAT REQUIRE SOME FORM OF MAINTENANCE OR ENGINEERING ATTENTION. PLANT REGISTER, PLANT INVENTORY, OR EQUIPMENT FAMILY TREE IDENTIFY & PRIORITIZE THE PHYSICAL RESOURCES.

STEP 1 - SELECT PLANT AREAS THAT MATTER : 

STEP 1 - SELECT PLANT AREAS THAT MATTER ASSESS THE IMPACT OF THE PHYSICAL RESOURCES ON THE KEY BUSINESS PERFORMANCE AREA. AVAILABILITY PROCESS CAPABILITY QUALITY COSTS SAFETY/ENVIRONMENTAL RISKS

STEP 1 - SELECT PLANT AREAS THAT MATTER : 

STEP 1 - SELECT PLANT AREAS THAT MATTER ESTABLISH THE BOUNDARIES BETWEEN EQUIPMENT SYSTEMS. DEFINES THE SCOPE OF THE REVIEW & ORGANIZES IT INTO MANAGEABLE PIECES.

STEP 2 – DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS : 

STEP 2 – DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS THE PURPOSE OF THE MAINTENANCE TACTIC IS TO MAKE SURE THE EQUIPMENT IS WORKING PROPERLY & PRODUCING ON SCHEDULE.

STEP 2 – DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS : 

STEP 2 – DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS CATEGORIES OF PHYSICAL ASSETS IN TERMS OF FUNCTION PRIMARY – WHY THE EQUIPMENT EXISTS AT ALL. SECONDARY – LESS OBVIOUS PRIMARY FUNCTION BUT THE CONSEQUENCES OF FAILURE MAY BE NO LESS SEVERE. PROTECTIVE

STEP 2 – DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS : 

STEP 2 – DETERMINE KEY FUNCTIONS & PRODUCTIVITY GOALS MAINTENANCE PERFORMANCE MAY BE DEFINED IN TERMS OF … BUILT-IN – WHAT IT CAN DO REQUIRED – WHAT WE WANT IT TO DO ACTUAL – WHAT IT IS DOING

STEP 3 – DETERMINE PLAUSIBLE FUNCTIONAL FAILURES : 

STEP 3 – DETERMINE PLAUSIBLE FUNCTIONAL FAILURES FUNCTIONAL FAILURES TOTAL LOSS OF FUNCTION PARTIAL LOSS OF FUNCTION MULTIPLE LEVELS OF PERFORMANCE EXPECTED FROM AN INDIVIDUAL FUNCTION.

STEP 4 – DETERMINE LIKELY FAILURE MODES AND THEIR EFFECTS : 

STEP 4 – DETERMINE LIKELY FAILURE MODES AND THEIR EFFECTS LIKELY FAILURE MODES THOSE THAT OCCURRED ON THE SAME OR SIMILAR EQUIPMENT. THOSE ALREADY THE SUBJECT OF PREVENTIVE MAINTENANCE TASKS. THOSE THAT HAVE NOT HAPPENED BUT ARE CONSIDERED POSSIBLE BECAUSE OF EXPERIENCE OR VENDOR/MANUFACTURER RECOMMENDATIONS.

STEP 4 – DETERMINE LIKELY FAILURE MODES AND THEIR EFFECTS : 

STEP 4 – DETERMINE LIKELY FAILURE MODES AND THEIR EFFECTS WHEN A FAILURE MODE OCCURS, OBTAIN THE FOLLOWING INFORMATION. THE EVIDENCE OF THE FAILURE TO THE OPERATING CREW UNDER NORMAL CONDITIONS. THE HAZARDS THE FAILURE MAY POSE TO WORKER SAFETY, PUBLIC SAFETY, PROCESS STABILITY, OR THE ENVIRONMENT. THE EFFECT ON PRODUCTION OUTPUT AND MAINTENANCE.

STEP 5 – SELECT FEASIBLE AND EFFECTIVE MAINTENANCE TACTICS : 

STEP 5 – SELECT FEASIBLE AND EFFECTIVE MAINTENANCE TACTICS PREVENTIVE MAINTENANCE TACTICS MUST BE … TECHNICALLY FEASIBLE – DEAL EFFECTIVELY WITH THE TECHNICAL CHARACTERISTIC OF THE FAILURE. COST-EFFECTIVE – REDUCING OR AVOIDING PITFALLS IN LINE WITH COSTS AND OPERATING CONSTRAINTS.

STEP 6 – IMPLEMENT SELECTED TACTICS : 

STEP 6 – IMPLEMENT SELECTED TACTICS ACTIONS NEEDED TO PUT THE MAINTENANCE TACTICS INTO EFFECT. TWEAKING MAINTENANCE SCHEDULES. DEVELOPING OR REVISING TASKS INSTRUCTIONS. SPECIFYING SPARE PARTS AND ADJUSTING INVENTORY LEVELS. ACQUIRING DIAGNOSTIC OR TEST EQUIPMENT. REVISING OPERATION AND MAINTENANCE PROCEDURES. SPECIFYING THE NEED FOR REPAIR OR RESTORATION PROCEDURES. CONDUCTING TRAINING IN THE NEW PROCEDURES.

STEP 7 – OPTIMIZE TACTICS AND PROGRAM : 

STEP 7 – OPTIMIZE TACTICS AND PROGRAM THE OBJECTIVE OF THIS ONGOING ACTIVITIES ARE TO REDUCE EQUIPMENT FAILURE, IMPROVE MAINTENANCE EFFECTIVENESS, THE USE OF RESOURCES, IDENTIFY THE NEED TO EXPAND THE REVIEW, AND REACT TO THE CHANGING INDUSTRY OR ECONOMIC CONDITIONS.

STEP 7 – OPTIMIZE TACTICS AND PROGRAM : 

STEP 7 – OPTIMIZE TACTICS AND PROGRAM COMPLIMENTARY ACTIVITIES PERIODIC RE-ASSESSMENT AND REVISION OF THE RCM REVIEW RESULTS. CONTINUOUS PROCESS OF MONITORING, FEEDBACK, AND ADAPTATION. ANALYZES AND ASSESSES THE DATA PRODUCED BY PRODUCTION AND MAINTENANCE ACTIVITIES FOR FAILURE RATES, CAUSES, AND TRENDS. VARIANCES BETWEEN ACTUAL AND TARGET PERFORMANCE.

RCM KEY SUCCESS FACTORS : 

RCM KEY SUCCESS FACTORS CLEAR PROJECT GOALS MANAGEMENT SUPPORT & A COMMITMENT TO INTRODUCE A CONTROLLED MAINTENANCE MANAGEMENT. UNION INVOLVEMENT GOOD UNDERSTANDING OF RCM PHILOSOPHY BY PLANT STAFF.

Slide 42: 

RCM KEY SUCCESS FACTORS PILOT RCM APPLICATIONS TO DEMONSTRATE SUCCESS & BUILD SUPPORT. SUFFICIENT RESOURCES FOR BOTH THE REVIEW AND SUBSEQUENT IMPLEMENTATION OF RECOMMENDATIONS. CLEAR DOCUMENTATION OF RESULTS TO FACILITATE ACCEPTANCE OF RECOMMENDATIONS. INTEGRATION WITH CONDITION-BASED MAINTENANCE CAPABILITY.

RCM IMPLEMENTATION PHASES : 

RCM IMPLEMENTATION PHASES

RELIABILITY-CENTERED MAINTENANCE (RCM) : 

RELIABILITY-CENTERED MAINTENANCE IS THE PROCESS OF DETERMINING THE MOST EFFECTIVE MAINTENANCEAPPROACH. AS THE AIRLINE INDUSTRY SHOWED 40 YEARS AGO, RCM CAN NOT ONLY IMPROVE THE RELIABILITY OF A SYSTEM, IT CAN SIGNIFICANTLY REDUCE THE REQUIRED MAINTENANCE. RELIABILITY-CENTERED MAINTENANCE (RCM)

RELIABILITY-CENTERED MAINTENANCE (RCM) : 

RELIABILITY-CENTERED MAINTENANCE (RCM) IN TODAY'S COMPETITIVE WORLD ECONOMY, THAT TRANSLATES INTO A LOT OF MONEY SAVED, BOTH FROM REDUCED FAILURES AND REDUCED WORK. A PROPERLY IMPLEMENTED RCM PROGRAM WILL CONTINUE SAVING MONEY YEAR AFTER YEAR.

Slide 46: 

TO REMAIN COMPETITIVE MOST COMPANIES CAN NO LONGER AFFORD TO REMAIN ON THE SIDELINES DOING THINGS LIKE THEY'VE ALWAYS DONE. LET RCM MOVE THE MAINTENANCE PROGRAM INTO THE 21ST CENTURY. RELIABILITY-CENTERED MAINTENANCE (RCM)