maintenance methodologies and history maintenance methodologies and history presented by: tim bair...

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Maintenance Methodologies and

History

Presented By:

Tim Bair & Jeff Banks

Research Engineers

The Applied Research Laboratory at

The Pennsylvania State University

Welcome to the CBM & RCM

“Short Course”

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Course Summary

• Introductions

• ARL Overview

• Class experience poll

• Course Overview

• Maintenance History

• Intro to CBM and RCM

• RCM Overview

• FMECA

• CBM Overview

• CBM examples

• Course Wrap-up/Feedback

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Biography: Tim Bair

• B.S. The Pennsylvania State University

• MS. Air Force Institute of Technology

• MS Industrial College of the Armed Forces

• Colonel, USAF (Ret)– Aircraft Maintenance/Logistics 26 years

– 13 assignments at flightline, numbered AF and HQ ACC, et al• Worked on F-16, A-10, F-15, F-4E, RF-4C, OV-10. F-106, T-33

• HQ ACC logistics lead for F-16 program

• Germany, Korea (2), AFROTC,

– Culminated as Dep. Director, Maintenance & Logistics, OO-ALC

• Current Work – Penn State Applied Research Lab – Director, Institute for Manufacturing and Sustainment Technologies

– iMAST is a Navy ManTech Center of Excellence

– Execute projects for NAVSEA, NAVAIR and MARCOR designed to save money in acquisition and life cycle cost

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Biography: Jeffrey Banks

• B.S. Mechanical Engineering – Villanova University– Worked as an intern at the CCA Paper Mill in Philadelphia as an assistant to

the Chief Maintenance Engineer

• M.S. Acoustics – The Pennsylvania State University– Graduate work involved developing unique sensor fusion technology for

detecting gear, bearing and shaft faults in mechanical systems.

• Industry – Mead Paper Company– Worked as a Diagnostic Engineer at the Corporate R&D Facility.

– Responsibilities involved traveling to Mead Corporation divisions to conduct diagnostic surveys; primarily to troubleshoot machine maintenance and process variability issues related to paper making processes and converting operations.

– Specialization in analyzing vibration\pulsation issues that affected manufacturing concerns, maintenance issues and capitol expansion.

• Current Work – Penn State Applied Research Lab – Department head & research engineer duties include RCM, CBM and

developing machinery health monitoring systems/diagnostic and prognostic technology for asset health management.

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“…maintains a special long-term strategic relationship with DoD for technology development and engineering applications.”

Established in 1945 by the Navy post WW II

Technology Areas

Materials & Mfr’ing S&T Comms and Information

Undersea Vehicles Power and Energy

Hydrodynamics and Structures Navigation

Acoustics & Quieting Undersea Weapons

Largest Interdisciplinary Research Unit at

Penn State – ~1200 faculty/engineers, staff,

students

Classified facilities and programs

Research Expenditures FY14 >$180M

Designated an University Affiliated Research

Center by DoD in 1996

•

•

•

•

•

•

•

•

We Are….

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Serve as a university center of

research excellence and advanced

capabilities for critical DoD

sciences and technology and

related applications.

Champion the transition of

advanced technology to

operational systems in support of

DoD acquisition programs, legacy

platforms and the defense industry.

Contribute to the education,

research, and service mission of

The Pennsylvania State University

VIRGINIA CLASS

STUDENT PHOTO

ARL Mission

ARMORED AND TACTICAL VEHICLES

F-35 JOINT STRIKE FIGHTER

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MISSION

To be the preeminent source of innovative technologies-materials, process,

manufacturing, design and logistics technologies for affordable, high

performance platform structures and systems.

Materials Processing Material Design and

Characterization

Process Development

Advanced Coatings

Advanced Composites Marine, Land, and

Aerospace Systems

– Design and Analysis

– Materials Char./Qual.

– Process Optimization

– NDE, Repair

Laser Processing Laser Physics

Process Technology

System Integration

Manufacturing Systems Automated Conceptual

Design/Trade Space Exploration

Simulation and Modeling for

Manufacturing

Shearography, Spectrometry,

Inspection, NDT

Environmental Technology

MAJOR PROGRAMSiMAST, Drivetrain Technology Center,

DTRA University Partnership,

Systems Operations & Automation

Condition Based Maintenance

Sense and Respond Logistics

Integrated Health Management

Materials and Manufacturing

Mission and Organization

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Class Introductions & Experience

Name

Job/Assignment

Alum of …?

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Maintenance 101

1903

2014

1st Gen: Me 262

MiG 15, F-86

2nd Gen: onboard radar,

IR missile tech

3rd Gen: F-4, ^IR & radar systems,

air-air prime, grnd attack avionics,

4th Gen: ^ maneuver, fly-by-wire, digital

avionics buses, F-15, 16, 18

5th Gen: LO tech, hi-perf engines, F-35

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Maintenance Methodologies

• All of these processes have a place. Operating Equipment Asset Management uses concepts and ideas from all four types of maintenance, assembled in a mix to best address safety, environmental, mission, business and site requirements.

Operating Equipment Asset Management by John Mitchell

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Reactive Maintenance

• Reactive Maintenance is corrective action applied on failure or obvious, unanticipated threat of failure: run-to-failure.

– Run-to-failure is simplistic, requires no forethought, and, at least up to the point of equipment failure, appears to require the least support.

• Not recommended if an unexpected failure can endanger personnel; release toxic; flammable or polluting material; interrupt production; or cause collateral damage.

• Reactive maintenance does make economic sense in some cases (replacing easily accessible light bulbs, fuses) but the decision to implement reactive maintenance must be based on probability, cost, and consequences.

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Preventive Maintenance (PM)

• Preventative Maintenance tasks include inspection, service and/or replacement conducted at regular, scheduled intervals.– Established to avoid failure

based on average statistical/anticipated lifetime.

• PM may be invasive, requiring an outage and disassembly for visual inspection and/or overhaul/replacement regardless of condition.

– The intervals between specific Preventive Maintenance tasks are based on average life, lead the fleet testing, scheduled Phase/ISO/PDM

• A PM program can be cost effective when equipment operation is consistent, average life is predictable within a reasonable span, failures are well understood, and useful failure statistics are available.

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1. Condition measurement consists of non-invasive measurements that define mechanical and operating condition

– Measurements may be made continuously (on-line) from installed transducers or periodically with portable equipment.

2. Condition monitoring and (health) assessment is the individual and collective comparison of condition measurements, value versus time trends to arrive at an appraisal of current condition, identify and analyze defects (diagnostics).

– Condition assessment is also directed at detecting and identifying degradation mechanisms.

3. Repair and Maintenance actions required as indicated by condition monitoring and health assessment—i.e. based on the objective evidence of need.

OPERATING EQUIPMENT ASSET MANAGEMENT YOUR 21ST CENTURY COMPETITIVE NECESSITY, By John S. Mitchell

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Predictive (PdM) or Condition

Based Maintenance (CBM)

• PdM/CBM: Maintenance action based on actual condition obtained from in-situ, non-invasive tests, operating and condition measurements.– Condition Based Maintenance has proven capable of identifying

faults early enough to minimize the impact of:

• operational interruptions

• avoid expensive failures

• including collateral damage

• significantly reduce the cost of maintenance.

• Some potential failures, such as fatigue, are not easily detected with condition measurements.

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Proactive Maintenance

• Proactive Maintenance (PCM): The collection of efforts to identify, monitor and control future failure with an emphasis on the understanding and elimination of the cause of failure.

• Proactive maintenance activities include:

– The development of design specifications to incorporate maintenance lessons learned and to ensure future maintainability and supportability.

– Performing root cause failure analysis to understand why in-service systems failed.

– The development of repair specifications to eliminate underlying causes of failure.

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Cost of Different Maintenance

Methodologies

• A study conducted by the power generating industry in 1986, reported lifecycle cost savings for PM in the range of 12 to 18 percent compared to reactive maintenance.

• PM significantly reduces Operations and Maintenance (O&M) costs compared to operate-to-failure; however, costly unexpected failures may still occur when the span between average and minimum lifetime is large

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Prognostics and Remaining

Useful Life (RUL)

• Currently, most CBM

technology provides

diagnostic information.

– Provides an indication of a

fault and a degree of

severity.

– Diagnostics does not

provide an accurate

indication of remaining

useful life of the equipment.

• Prognostics: is the ability to

accurately predict when a

component, system or

equipment will fail.

• A RUL prediction provides for the

most effective management of an

asset.

– Plan maintenance actions

– Get the most life out of equipment

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Maintenance Methodology

Progression

• Over the years, industry, in general, has recognized that migrating from reactive or breakdown maintenance to condition-based maintenance has the dual advantage of increased effectiveness and decreased cost


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Comprehensive Maintenance

• Practitioners recognize that a

comprehensive equipment

management strategy will

include a blend of:

– Reactive Maintenance

– Preventive Maintenance

– Condition-Based

Maintenance

– Proactive Maintenance

• To be applied based on the

specific circumstances,

probability, and consequences

(risk) of failure

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CBM is coming to a flightline

near you!

• So what is DoD doing

about it?

• And when will I see it

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DoD Initiative: CBM+

• CBM+ focuses on inserting technologies that improve

maintenance capabilities and processes into both new and

legacy weapon systems and integrates the support elements to

enable enhanced maintenance-centric logistics system

responses.

• CBM+ includes a conscious effort

to shift equipment maintenance

from an unscheduled, reactive

approach at the time of failure to

a more proactive and predictive

(CBM) approach that is driven by

condition sensing and integrated,

analysis-based decisions.

Reference: Condition Based Maintenance Plus DoD Guidebook, May 2008

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CBM+ (per DAU)

• Condition-based maintenance (CBM+) can be defined as a

set of maintenance processes and capabilities derived, in

large part, from real-time assessment of weapon system

condition obtained from embedded sensors and/or external

tests and measurements using portable equipment. The

goal of CBM+ is to perform maintenance only upon

evidence of need. The desirable outcome of CBM+ is a

force of maintainers with knowledge, skill sets, and tools for

timely maintenance of complex systems through use of

technologies that improve maintenance decisions and

integrate the logistics processes.

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CBM+ (per DAU)

• CBM+ focuses on inserting, into both new and legacy weapon systems, technology to

support improved maintenance capabilities and business processes. It also involves

integrating and changing business processes to dramatically improve logistics

system responsiveness. Under consideration are capabilities such as enhanced

Prognostics & Health Management (PHM) and Enhanced Diagnostics techniques,

failure trend analysis, electronic portable or point of maintenance aids, serial item

management, automatic identification technology and data-driven interactive

maintenance training. The ultimate intent of this initiative is to increase

operational availability and readiness throughout the weapon system life cycle at a

reduced cost. CBM+ will help predict a system's remaining operational life span,

support operator decision-making, interface with control systems, aid maintenance

repairs, and provide feedback to the logistics support and system design

communities. Specific Capabilities include:

· Enhanced prognostic and diagnostic techniques

· Failure trend analysis

· Electronic portable or point-of-maintenance aids

· Serial item management

· Automatic identification technology

· Data-driven interactive maintenance training

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Air Force CBM+

• Condition Based Maintenance (CBM) utilizes real time

assessment of weapon system condition obtained from

embedded sensors and/or external test and

measurements using portable equipment.

– The goal of CBM is to perform maintenance only upon

evidence of need.

• “CBM+ expands upon these basic concepts by

encompassing other technologies, processes, and

procedures that enable improved maintenance and logistic

practices.”

Reference: Air Force Condition Based Maintenance + Fact Sheet

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Air Force CBM+

• “Ten enabling technologies and concepts constitute the

initial Air Force baseline for achieving the DoD vision for

CBM+ implementation”:

– Prognostics

– Diagnostics

– Portable Maintenance Aid

– Interactive Electronic Technical Manuals

– Interactive Training

– Data Analysis

– Integrated Information Systems

– Automatic Identification Technology

– Reliability Centered Maintenance

– Joint Total Asset Visibility

Reference: Air Force Condition Based Maintenance + Fact Sheet

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Plus (CBM+)(from AFRL CBM+ Research Environment brief)

• DoDD 4151.18 – Maintenance of Military Materiel – Mar 2004

• AFI 63-107 – Integrated Product Support Planning and Assessment – Nov 2004

• DODI 4151.22 – CBM+ Policy – Dec 2007

• DoD CBM+ Guidebook – May 2008

. . . “ the application and integration of appropriate processes, technologies, and knowledge-based capabilities to improve the reliability and maintenance effectiveness of DoD systems and components.”

Polic

y &

Guid

ance

Form

al

Definitio

nA

F S

olu

tions

Develop &

Sustain

Warfighting

Systems

(D&SWS)

AF Transformation

Supply Chain

Operations

Systems Lifecycle Integrity Management (SLIM)

CBM+ (Prognostics

RUL, Diagnostics)

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CBM+ for JSF

• CBM+ is supported by

automated

maintenance

information systems

that seamlessly

integrate with other

logistics systems.

• This leads to more

efficient maintenance,

better readiness, and

the cost savings

associated with

smaller logistics

footprints.Reference: Air Force Condition Based Maintenance + Fact Sheet

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Reliability Centered Maintenance

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The RCM Process

• How to best design a maintenance management

strategy for your assets or platforms?

– Which methodologies will allow for the most effective

and efficient operation and maintenance of each asset.

• The Reliability Centered Maintenance process is

used to determine which type or combination of

maintenance methodologies is most appropriate

and effective for operating highly reliable and

productive assets and platforms.

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History of RCM

• ‘Reliability-Centered Maintenance (RCM) was initially developed by the commercial aviation industry to improve the safety and reliability of their equipment.’

• In 1974, the Department of Defense commissioned United Airlines to report on standard maintenance practices and programs for commercial aircraft.

• In 1978, a report written by Stanley Nowlan and Howard Heap and titled Reliability Centered Maintenance was released which documented RCM for the first time.

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Preventative Maintenance in the

Airline Industry

• Previous to the Nowlan and Heap report in 1978 the traditional maintenance approach in the commercial airline industry was to perform scheduled maintenance at fixed time intervals – Preventative Maintenance (PM).

• PM assumes that failure probabilities can be determined statistically for equipment and components so that corrective action can be taken to prevent catastrophic failure.

Reliability Centered Maintenance, By Nowlan and Heap

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Preventative Maintenance:

Assumptions

• Correlation between age and/or usage and failure rate.

Increased Age or Usage = Increased Probability of Failure

• For many systems and components this assumption is not valid.

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Findings from the RCM Report

• What was found through the maintenance study:

– Scheduled overhaul has little effect on the overall reliability of a complex item unless the item has a dominant failure mode.

– There are many items for which there is no effective form of scheduled maintenance.

• Preventative maintenance alone is not the most effective methodology for conducting maintenance.

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Conclusions from the RCM

Report

• A better understanding of the failure process in complex equipment has actually improved reliability by making it possible to direct preventative tasks at specific evidence of potential failure. – More effective to perform maintenance based on current

and future predicted condition of the equipment.

• Use a systematic approach to evaluate:– Functions and failure modes of a system

– Assess the risk and criticality of the failure modes

– Perform a defined decision process to evaluate the most effective form of maintenance for each system and application.

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Summary

• There are several maintenance methodologies that

can be used to perform maintenance.

• RCM is a process that helps evaluate the most

effective methodology and combination of

methodologies for achieving a high reliability for the

system being maintained.

– Applied maintenance will be system, equipment and

component specific.

– Dependent upon the application and the operating context

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A Reduction in Total Life Cycle Costs with

Reliability Centered Maintenance (RCM) and

Condition Based Maintenance (CBM+)

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Department of Defense:

RCM Policy

• DoD Manual Number 4151.22-M, June 30, 2011

• POLICY. “it is DoD policy that, as one of the key enablers

of Condition Based Maintenance Plus (CBM+) and the

life-cycle sustainment of DoD weapon systems, RCM shall

be used to ensure effective maintenance processes are

implemented.”

– ‘Direct incorporation of RCM throughout the total system

life cycle, from requirements development through

disposal.’

– ‘There is a close relationship between RCM and CBM+. RCM

provides the evidence of need for other CBM+ processes

and technologies, such as health monitoring or prognostics.’

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Logistics Effort that Support

TLCSM

• Total Life Cycle System

Management (TLCSM) sets

goals, tracks progress and

status, and balances

resources to accomplish

desired material readiness.

Reference: Condition Based Maintenance Plus DoD Guidebook, May 2008

• CBM+, in concert with the other TLCSM tools will enhance

materiel readiness:

– CPI: Continuous Process Improvement

– M&S: Cause-and-effect predictive modeling and simulation

– PBL: Desired outcomes achieved through Performance

Based Logistics

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Total Ownership Cost

Nominal Life-Cycle Cost of Typical DOD Acquisition Program with a 30-Year Service Life

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Total Ownership Cost

• Studies show that about

85 percent of the

operating and support

costs of a weapon system

will be determined as

soon as requirements are

set, while less than 10

percent of the life-cycle

cost have been spent.

• By the time a product is

ready for production, over

90 percent of the

operating and support

costs have been

determined, and about 28

percent of the total life-

cycle costs have been

spent.

United States General Accounting Office, Report to the Subcommittee on Readiness and

Management Support, Committee on Armed Services, U.S. Senate, ‘Setting Requirements Differently

Could Reduce Weapon Systems’ Total Ownership Costs’ February 2003

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Aviation Applied Technology

Directorate (AATD)

The Army S&T goal to decrease O&S cost by reducing maintenance,

which was derived from the Rotary Wing Vehicle Technology Development

Approach and the Aviation S&T Strategic Planning Workshops, supports

this transition to CBM.

• Specific 2013 program metrics:

• 50% Reduction in Inspections/ Flight Hour

• 12% Reduction in Maintenance Labor/ Flight Hour

• 15% Increase in Component Mean Time between Removals

• less than 5% False Removal Rates and 10 hr detection time before

failure measured against a 2005 fielded aircraft baseline.

An integrated set of technologies is required to provide aviation platforms

the ability to accurately assess health and project failure of critical aircraft

components, based on actual usage in operational environments.

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Maintenance and Cost

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Maintenance and Availability

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CBM+ Benefits that Reduce O&S Costs

• Diagnostic

– Reduce Misdiagnosis/NFF: It is difficult to determine rate of occurrence

accurately but rough determination by system or component can be

made with conservative engineering estimates.

• Restocking fee cost avoidance for reducing NFF’s

• Disposal cost avoidance for misdiagnosed parts like batteries.

• Predictive/Prognostic:

– Avoid Catastrophic Failure: Detect and alleviate fault before significant

damage occurs, which may eliminate a total component rebuild.

– Collateral Damage: Detect and alleviate fault before significant damage

occurs may eliminate damage to other components/systems.

• Other Benefits:

– Availability: CBM enables increased availability through predictable

maintenance activity.

– Contract Logistic Services: Potentially reduce the number of support

Field Service Representative (FSR) with the implementation of

embedded health management technology.

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Questions?

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