rcm made easy

8/9/2019 RCM made Easy

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RCMBlitzTM

RCM Made Simple

Introduction to RCM Blitz

Presented by:

What would you do with more

free time?

World-Wide RCM Discipline Leader

GPAllied

Copyright 2008 Allied Reliability, Inc.


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RCMBlitzTM

Welcome to our RCM Blitz!

When it comes to building a complete maintenance

designed reliability of an asset, there is no other toolavailable that has the success record of traditional RCM.

Doug Plucknette

Using RCM Blitz



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RCMBlitzTM

Specific Benefits of Applying the RCM to

our rocess

Your Company will be able to develop a

complete maintenance strategy for yourequipment that includes clearly written and

prec se preven ve an pre c ve

maintenance tasks

Your Company will be able to put into place

failure-finding tasks that wil l reduce the

probability of catastrophic HSE (Health,Safety, Environmental) failures



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Specific Benefits of Applying the RCM

e o o our rocess, con

Your Company will learn how to reduce MTTR

(Mean Time To Restore) through the use ofConsequence Reduction Tasks

our ompany w e a e o e erm ne e

spare parts that need to be stored on site

Your Company wil l learn how to identify where

to apply the RCM Blitz process based on

Reliability Measures



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RCMBlitzTM


Reduce Emergency/Demand maintenance work


Reduce maintenance costs by reducingsecondary equipment damage

e uce un cos o pro uc y ower ngmaintenance costs and improving OverallE ui ment Effectiveness OEE

Increase the understanding of how yourequipment is supposed to work for both

opera ons an ma n enance peop e



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Develop a detailed and effective

troubleshooting guide based on actual failurealarms, effects and symptoms

eve op e a e opera ons c ec s s o

ensure proper set-up and operation of

-

airline industry be without checklists?)

Learn how to apply the RCM process to new

equipment designs



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The History of RCM

US DOD and United Airlines

Utilit ies Industry

Manufacturing

Commercial Standards for RCM

PASS55



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Various Approaches to RCM

Traditional SAE J1011

7 Steps

Streamlined



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Section 4 RCM MaintenanceStrate ies

RCMBlitzTM


free time?



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Maintenance Tasks

The key to ensuring the designed reliability

of your process is selecting the correct

maintenance task to address a specificfailure mode or cause of failure



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Maintenance Tasks, contd

In RCM we have 5 types of maintenance tasks

1. On-condition Maintenance

.

3. Failure Finding

.

5. Run to Failure



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On-Condition Maintenance

A maintenance task that is put into place to

detect failure resistance to a specific failure

mode

The detection of failure is based on a known

potential failure condition



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Traditional Types of On-Condition

a n enance

Vibration Analysis

Thermography Ultrasonic Testing

Tribology

Non-Destructive Testin

Motor Current Analysis



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Non-Traditional Types of On-Condition

a n enance

Human Senses



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How PdM Works Early Identification of

e ec s

P

F



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Completing the P-F Curve

RCM Reliability Centered Maintenance

FMEA

Design RCM Blitz

Five Rights of Reliability

Precision Alignment

Precision Balancing

Installation Standards

Torque Specifications

Precision Tools e ec upp er greemen s

Requirements Documents

Design Standards

Proactive Maintenance/Reliabilit Tasks PdM Tasks

Reactive

Maintenance

I Installation

o

Failure

P Potential Failure

istancet

Failure

P-F IntervalI-P Interval

T - Time

Re


The Modified P-F Curve and I-P Interval are intellectual property o f Reliability Solutions, Inc. (Patent Pending)


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Preventive Maintenance (PM) Tasks

Preventive maintenance is time based, it isperformed on equipment that has a knownage or use u e

These tasks should be set up to prevent

failure patterns (A-C)

Scheduled Ins ection Scheduled Reworkand Scheduled Discard are preventivemaintenance tasks



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Failure Finding Tasks

Scheduled inspections of a hidden function

item, intended to find functional failures that

have already occurred but are not evident tothe operating crew

The objective of a failure finding task is toensure adequate availability of a hidden

function



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Redesign

Any change in equipment, process, orprocedures

In order for a redesign to be considered

Eliminate the failureBe cost effective

Reduce the conditional probabil ity of failure to an

Change the function of an item from hidden toevident



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No Scheduled Maintenance

This becomes the maintenance strategy

when there is no applicable or effective task,

or no applicable or effective redesign

*When No Scheduled Maintenance is your

maintenance strategy, you must put in place a



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Consequence Reduction Strategy

When no schedule maintenance is the only

remaining strategy, it becomes important to

make sure you have the proper spare parts,resources and procedures in place to reduce

e consequence o e a ure



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Pulling It All Together

So how is all of this accomplished?

Apply the RCMBlitz process to your equipment!



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Section 5 The RCMProcess

RCMBlitzTM


free time?



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The 7 Steps of Reliability Centered Maintenance

Traditional RCM Methodologies fit this 7-step process defined by

SAE standard JA1011:

1. What are the functions of the asset?2. In what way can the asset fail to fulfill its functions?

3. What causes each functional failure?

4. What happens when each failure occurs?5. What are the consequences of each failure?

6. What should be done to prevent or predict the failure?

7. What should be done if a suitable proactive task cannot be found?


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The RCM Process

1. List the Process Functions

2. List the Functional Failures

3. List the Failure Modes and Probability ofFailure

4. Describe the Failure Effects

6. Run the Failure Mode through the RCM

Decision Process

7. Select a Maintenance Task and assess

spare parts


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Listing Functions

Function

The normal or characteristic actions of an item,

defined in terms of performance capabil ities

Point at which you actually begin your RCM

Listing the system and component functions is a

ke ste in the RCM rocess

The first function we list will be the System

Function or Main Function

The System Function wil l clearly state what theintent of the process is, and the performance

standards it is ex ected to maintain


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Main Function

The Main Function or System Function

The reason the asset or process exists including

the expectation of the process and performance

standards we need to maintain

Example Main Function

If ou were about to anal ze a rocess that made #2pencils, your main function would be:

. o e a e o ma e penc s a a ra e o un s per

hour, while meeting all quality, safety, health, and

environmental standards


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Main Function, contd

Once you have listed the Main Function and

determined the performance standards, you

will move on to l ist all of the supportfunctions


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Support Functions

Describe the functionality of each component within

the system

The support function for fuel piping would be:

To be able to contain and transport fuel

The support function for a gear box would be:

To be able to reduce RPM by a 4 to 1 ratio

The support function for a E-Stop button would be:

of an emergency

A support function for equipment structure would be:


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Hidden Functions

Functions that will not be evident to the

operating crew under performance of their

normal dutiesIn a high level probe a hidden function would be:To be capable of shuting down tank supply when it

reaches a set level

The function of this device during normal operations

of the system is not evident to the operator


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Functional Failure

Failure of an item to perform its normal

actions within specified performance

standards The functional failure is phrased as the

inverse of the function


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Functional Failure, contd

There may be one or more functional failures

for every function

Main Function1. To be able to make # 2 pencils at a rate of 1200

un s per our w e mee ng qua y, ea ,

safety and Environmental standards

Functional Failure1. 1. Unable to make #2 pencils at all

1. 2. Unable to make pencils at a rate of 1200 per hr

. . na e o mee qua y s an ar s1. 4. Unable to maintain health, safety and

environmental standards


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Failure Modes

The specific manner of failure; the

circumstances or sequence of events which

leads to functional failure

Should be written in a way that describes the Part,

Problem, and the Specific Cause of failure

Seized (Problem)

Fails due to lack of lubrication (specif ic cause)


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Failure Modes, contd

When listing Failure Modes you should

remember to include:

All failure modes that have occurredAll dominant failure modes

Failure modes that are likely to occur

Failure modes that have occurred on similar


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Do Not List:

Failure modes that are highly unlikely to occur!


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When listing failure modes, be sure to write

them at root cause level

Failure modes should be written at the level of

which you maintain the equipment


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Failure Effects

The immediate physical effects of a

functional failure on surrounding items and

on the functional capabil ity of the equipment

Failure Effects are the principal determinant

of failure consequences


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Failure Effects, contd

Failure Effect statements should include:

Events that lead up to the failure

The first sign of evidence by which the operating

crew will recognize the failure has occurred

failure

Events required to bring the process back tonormal operating condition


RCMBlitzTM


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Example Failure Effect Statement

Failure Mode Fuel pump bearing seized dueto lack of lubrication

Failure Effect Statement

Without proper lubrication, the pump bearing wil l heat up, vibrate

and if left to its own devices eventuall seize events leadin uto the failure) When the bearing fails the pump shuts down, theflow switch will alarm the operators when the flow falls below75 gpm for more than one minute (operators first sign of

will again shut down Operator will call maintenance to troubleshoot, repair and replace (events required to bring process tonormal operating condition)


RCMBlitzTM


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The RCM Decision Process

Uses a series of questions to determine:

The consequence category of the failure

A maintenance task to predict the failure

A maintenance task to prevent the failure

A redesign task to eliminate the failure

A failure finding task to reduce the probability of

An inspection that reduces the probability of

failure to an acceptable level

A consequence reduction task to reduce MTTR forrun to failure decisions


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Failure Consequences

The first step in the RCM decision processis to locate the correct category for thea ure consequence

ac a ure o e w a n o one o esefour categories:

Hidden Failure Conse uences Health, Safety, or Environmental Consequences

Operational Consequences

Non-Operational Consequences


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Hidden Failure Consequences

Consequences that result from the failure of

a Hidden Function

The failure of this device wil l not be evident

to the operating crew during the performance

of their normal duties


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Hidden Failures

Examples of components with Hidden

Functions:

Emergency Stop Switches

High Level Switches

Relief Valves

Rupture Discs

ressure w c es

Redundant Devices


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Health, Safety, and Environmental

onsequences

Consequences resulting from a functionalfailure that could have a direct adverse effect

on health, safety, or environment


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Operational Consequences

The economic consequences of a failure that

interferes with the planned use of operating

equipment

Examples of Operational Consequences:

Cost of lost production

os o ma n enance

Cost of replacement parts

Cost of waste


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Non-Operational Consequences

The economic consequences of a failure that

does not affect safety or the operational

capability of the equipment

Typically these are non-signif icant items that

have no hidden functions



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S P t


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Spare Parts

No maintenance strategy is complete without

assessing spare parts

Having the correct spares in place is critical in

reducing failure consequences

We use a risk based flow diagram to make

spare parts decisions


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Section 6 RCM Implementation

RCMBlitzTM


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RCMBlitzTM

RCM I l t ti


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RCM Implementation

Your RCM analysis is not complete until all

tasks have been implemented

Each Task should be assi ned to a s ecific

person and assigned a due date

Implementation can be tracked in the

database


RCMBlitzTM

RCM Management Review Meetings


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RCM Management Review Meetings

Communication is crit ical to successful

ommun ca e success


RCMBlitzTM

Barriers to Successful Implementation


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Barriers to Successful Implementation

Failure to prioritize tasks

Unrealistic due dates

Analysis/Task ownership

Resource allocation


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Questions?

rsm gpa e .com
