the naval sea systems command (navsea) reliability centered maintenance (rcm) & condition based...

The Naval Sea Systems Command (NAVSEA)

Reliability Centered Maintenance (RCM) &

Condition Based Maintenance Plus (CBM+) Programs

PRESENTED BY

Marc BorkowskiRonald GraffiusFebruary 25, 2015

Distribution Statement A: Approved for Public Release; Distribution Unlimited

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BLUF• NAVSEA’s RCM methodology optimizes maintenance costs

while maintaining inherent reliability of equipment and systems.

• NAVSEA’s RCM training and certification program provides NAVSEA with a standard engineering analysis methodology for determining maintenance requirement tasks for Operational, Intermediate and Depot Level maintenance.

• NAVSEA embraces advanced technology that reduce maintenance costs while increasing reliability through the use of sensor based technologies and prognostic health monitoring.

• CBM+ builds upon Navy’s CBM strategy of performing maintenance based on the objective evidence of need.

• NAVSEA plans to increase the use of CBM+ technologies where applicable and cost effective.

2Distribution Statement A: Approved for Public Release; Distribution Unlimited


NAVSEASolving Fleet Maintenance Problems

Distribution Statement A: Approved for Public Release; Distribution Unlimited 3


4

US NAVY Maintenance Policy (Highest Level)

United States Constitution

To provide and maintain a Navy (Article I, Section VIII)



6

What is RCM ?

• RCM is a logical, structured process to determine optimal maintenance for any system or equipment. – “Optimal” includes risk management - safety (sailors),

environment (law or regulations), mission and economics.

• RCM applied throughout the life cycle enables continuous process improvement on maintenance actions.

• RCM defines what must be done to achieve desired levels of safety and readiness at the best cost.



RCM & CBM+ Relationship

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CBM is a Maintenance philosophy based on

“evidence of need”

CBM is a Maintenance philosophy based on

“evidence of need”

RCM Provides Rules of Evidence

RCM Provides Rules of Evidence



NAVSEAINST RCM, CBM, CBM+ 2009, updated 2013

NAVSEAINST RCM, CBM, CBM+ 2009, updated 2013

DODI 4151.22

CBM+ 2007, updated 2012

DODI 4151.22

CBM+ 2007, updated 2012

8

History of RCM, CBM, & CBM+ at NAVSEA

RCM and CBM began with the Airline Industry in the 1970s and was adopted by NAVSEA soon after. CBM is the policy of how we maintain our ships today.

Nowlan & HeapReliability Centered

Maintenance1978

Nowlan & HeapReliability Centered

Maintenance1978

NAVSEAMIL-P-24534A

1985

NAVSEAMIL-P-24534A

1985

Integrated Condition

Assessment System (ICAS)

1995

Integrated Condition

Assessment System (ICAS)

1995

SMARTSHIP RCM AND

FLEETMER1996

SMARTSHIP RCM AND

FLEETMER1996

OPNAV CBM POLICY

2007(Now Updating)

OPNAV CBM POLICY

2007(Now Updating)

MCM CBM& DS Study

2010

MCM CBM& DS Study

2010

MIL-STD 3034A 2014

MIL-STD 3034A 2014



NAVSEA RCM Goals & Processes

RCM Goals: • Develop cost effective

maintenance procedures that preserve system functions

• Evaluate and standardize maintenance across platforms

• Continuous process improvement via FLEETMERs & RCM Workshops

9

RCM Processes:• MIL-STD 3034A RCM

– Step by step RCM Process– Available for use by all services

• DoD 4151.22M– RCM program management

• NAVSEA RCM Manual– Describes fundamentals of Level I

and Level II RCM• Contract Data Requirements List (CDRL)

and Data Item Description (DID) supported for Acquisition, Technology & Logistics (AT&L)



MIL-STD 3034A“Reliability Centered Maintenance Process”

• Updated and released in April 2014 • Navy standard, but available to all services• 12 phase fully detailed RCM process• Associated Data Item Descriptions (DIDs) for each phase

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https://assist.dla.milQuicksearch= RCM



RCM & CBM+ Data Item Descriptions (DIDs)

1. DI-SESS-80991A Planned Maintenance System (PMS) Maintenance Requirement Card (MRC)2. DI-SESS-80992A PMS Maintenance Index Page (MIP) 3. DI-MNTY-80990 PMS RCM Documentation Control Sheet4. DI-SESS-80979A RCM Master System and Subsystem Index (MSSI)5. DI-SESS-80980A RCM Failure Modes and Effects Analysis (FMEA) Report 6. DI-SESS-80981A RCM Functional Failure Analysis (FFA) Report 7. DI-SESS-80982A RCM Functionally Significant Item (FSI) Index8. DI-SESS-80983A RCM Additional Functionally Significant Item (AFSI) Selection Report 9. DI-SESS-80984A RCM Logic Tree Analysis (LTA) with Supporting Rationale and Justification Report 10. DI-SESS-80985A RCM Servicing and Lubrication Analysis (SLA) Report11. DI-SESS-80986A RCM Maintenance Requirement Index (MRI) 12. DI-SESS-80987A RCM Procedure Validation Report 13. DI-SESS-80988A RCM Task Definition Report14. DI-SESS-80989A RCM Inactive Equipment Maintenance (IEM) Requirement Analysis Report15. DI-SESS-80994A RCM Functional Block Diagram (FBD) 16. DI-SESS-81823A RCM Class Maintenance Plan (CMP) 17. DI-SESS-81829 RCM Corrective Maintenance (CM) Development Report 18. DI-MGMT-81915 Condition Based Maintenance Plus (CBM+) Program Plan

These DIDs are available on the DoD Assist website: http://quicksearch.dla.mil/11Distribution Statement A: Approved for Public Release; Distribution Unlimited


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Two RCM ProcessesClassic RCM Process

Partitioning

Interfaces

FFA

ID Functions

FMEARisk Management

RCM Logic

How accurate was FMEA?

Does PM “Pay for Itself?”

How well does PM work?

Age Degradation

Applicability

EffectivenessBackfit RCM Process

Continuous Improvement

(MIL-STD 3034A)

(MIL-STD-3034A)



Backfit RCM Process



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NAVSEA’s RCM Process

Performing the right maintenance on the right equipment at the right interval maximizes

Ao and ROI

Payoff• > 40% average maintenance

manhour reduction since RCM enacted in 1997

• Since 2001, over 9000 personnel RCM Certified

• Additional savings in resources, asset management, logistics footprint and improved availability (collecting data for these metrics)

Performance• Best Manufacturing Practices

Center of Excellence award 2007• Consistent, repeatable, auditable

process for maintenance development

• Evaluates systems at failure mode• Applies to Ships, Carriers &

Submarines



MIL-STD 3034A Current Maintenance Development

• NAVSEA early insertion of RCM in the acquisition process

– DDG-1000 Zumwalt Class Destroyer

• 112 systems – RCM analyses conducted

– CVN-78 Gerald R. Ford Class Carrier• 22 new HM&E systems in progress• EM Catapults, Weps Elevators, Degaussing, etc.

– Littoral Combat Ships (LCS) Freedom Class• 85 systems – RCM analyses conducted • LCS Mission Modules RCM workshops

– Ohio Class Replacement • Using RCM MIL-STD per contract



RCM in Action • Common Maintenance Planning WG

– Improving Maintenance Requirements and Procedures across surface ships, submarines and carriers

– Realize lowest possible cost over expected service life– Achieve required level of ship and equipment reliability– Provide required level of ship and personnel safety by:

• Reviewing Maintenance Requirements and Procedures for Organizational, Intermediate and Depot Level Maintenance

• Developing Common Assessment Procedures (CAPs)• Discovering best practices• Improving maintenance policy and processes• Identifying and adapting new technologies to solve

maintenance problems16



RCM In ActionContinuous Process Improvement

• CMPWG Products– FLEETMER

• RCM analysis of existing maintenance “Back-fit”• Broad cross enterprise look at multiple related systems• Prioritized using stakeholder input of high maintenance burdened

systems– Common Maintenance Requirements Alignment MER

• Deep dive study of one system or equipment across all ships and enterprises

• Back to the basics area review of underlying technical rationale• Sweeping best practices research and evaluation• Flexible process with broad stakeholder involvement

• NAVSEA RCM Classic Workshops– Classic RCM analysis– Narrowly focused deep look at specific equipment or component– Used across NAVSEA enterprise



RCM Certification at NAVSEA

• RCM Training & Certification Program• Level I – Basic fundamentals and “Backfit RCM”

process– Two day course of instruction

• Level II – “Classic RCM” – One week course of instruction– How to develop maintenance requirements

• Level III – Train the trainer– Government only– Two week course of instruction– Level I and Level II plus experience– Required to re-certify annually

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NAVSEA provides:



RCM Certification

• RCM Training & Certification Program– Certifications are valid for three years– Recertification available online via electronic Planned

Maintenance System Management Information System Gateway or classroom

– Over 9000 students trained since inception in 2001

• DAU RCM Training– Fundamentals of RCM (2 hour course)– DAU Continuous Learning Module CLL-030

(www.dau.mil)



FY15 NAVSEA Reliability Centered Maintenance Certification Training Schedule and Locations

Indiana• 4/13/15 Crane (NSWC) –

L2• 4/20/15 Crane (NSWC) –

L1

New Hampshire• 3/2/15 Dover (SUBMEPP) – L2• 3/9/15 Dover (SUBMEPP) – L1• 7/13/15 Portsmouth (FLEETMER 85)– L1• 9/21/15 Dover (SUBMEPP) – L2• 9/28/15 Dover (SUBMEPP) – L1

Rhode Island• 11/18/14 Newport (NUWC) –

L1• 5/5/15 Newport (NUWC) – L1• 9/14/15 Newport (NUWC) –

L2

Washington• 3/16/15 Keyport (NUWC) – L2• 3/23/15 Keyport (NUWC) – L1

California• 11/6/14 San Diego

(SURFPAC) – L1• 11/13/14 Port Hueneme (NSWC PHD) – L1• 3/9/15 San Diego (SPAWAR) – L2• 3/16/15 San Diego (FLEETMER 83 )– L1• 4/13/15 Port Hueneme (NSWC PHD) – L2• 4/20/15 Port Hueneme (NSWC PHD) – L1• 9/14/15 San Diego (FLEETMER 86) – L1• 9/21/15 San Diego (SPAWAR) – L2

Florida• 12/8/14 Mayport (FLEETMER 81)

– L1• 1/26/15 Panama City (NSWC) – L2• 2/2/15 Panama City (NSWC) – L1

New Jersey• 10/20/14 Lakehurst (NAVAIR) – L2• 10/27/14 Lakehurst (NAVAIR) – L1• 6/8/15 Picatinny Arsenal (NSWC) – L2• 6/15/15 Picatinny Arsenal (NSWC) – L1

Virginia• 10/1/14 Norfolk (INSURV)– L1• 10/6/14 Portsmouth (CPA) – L2• 11/10/14 Suffolk (ISHPI) – L2• 11/17/14 Fairfax (SEA04RM) – L2• 12/17/14 Fairfax (SEA04RM) – L1• 2/10/15 Fairfax (SEA04RM) – L1• 4/20/15 Norfolk (SURFMEPP) – L2• 5/11/15 Norfolk (FLEETMER 84) –

L1• 5/18/15 Fairfax (SEA04RM) – L2• 7/6/15 Fairfax (SEA04RM) – L2• 7/22/15 Fairfax (SEA04RM) – L1• 8/10/15 Portsmouth (CPA) – L2• 8/17/15 Portsmouth (CPA) – L1• 8/24/15 Norfolk (NSLC) – L2• 8/31/15 Norfolk (NSLC) – L1

Pennsylvania• 10/16/14 Philadelphia (NSWCCD) –

L1• 10/20/14 Philadelphia (NSWCCD) –

L2• 2/4/15 Philadelphia (NSWCCD)– L1• 2/23/15 Mechanicsburg (NSLC) –




L1

FY15 RCM Certification Training Schedule promulgated NAVY msg: DTG 231742Z SEP 14 COMNAVSEASYSCOM

Maryland• 8/10/15 Baltimore (USCG) – L2• 8/17/15 Baltimore (USCG) – L1

Hawaii• 1/26/15 Pearl Harbor (FLEETMER 82) – L1

Distribution Statement A: Approved for Public Release; Distribution Unlimited 20


RCM & CBM+ PolicyThe following policy documents require or govern the use of RCM, CBM and CBM+ across DoD and

Navy:

DODI 4151.22 CBM+ for Materiel Maintenance Capstone policy instruction that drives CBM+ policy for NAVSEA.

OPNAVINST 4790.16A (Chief of Naval Operations CBM Policy) Establishes policy and responsibility for the implementation and integration of Condition-Based Maintenance (CBM) for naval ship,

submarine, aircraft systems, equipment and infrastructure.

OPNAVINST 4700.7L (CNO Maintenance Policy for US Navy Ships)Establishes maintenance policy for U.S. Navy ships and directs the common use of NAVSEA’s Reliability Centered Maintenance (RCM)

methodology in developing maintenance require ments.

OPNAVINST 4790.4E (CNO Ships’ Maintenance & Materiel Management Policy) Establishes policy and assigns responsibilities for the Ship’s 3-M System which is designed to provide for managing maintenance and

maintenance support to achieve maximum equipment operation readiness.

NAVSEAINST 4790.27A (NAVSEA RCM, CBM, & CBM+ Policy for Ships, Ship Systems and Equipment) Aligns NAVSEA policy with DoD and OPNAV’s RCM, CBM and CBM+ policies, specifically, requiring RCM based maintenance and the

establishment of a CBM+ Executive Steering Committee (Flag and SES level) and CBM+ Task Force (TF).

MIL-STD 3034A (Reliability Centered Maintenance (RCM) Process)Delineates the 12 phase fully detailed RCM Process and includes the associated Data Item Descriptions (DIDs) for each phase. Appendix

F describes relationships between RCM and CBM+. It is available for use by all Services.21



What is CBM+?

1. At its core, CBM+ is Condition Based Maintenance based on evidence of need provided by RCM analysis and other enabling processes and technologies.

2. CBM+ uses a systems engineering approach to collect data and enable analysis to support the decision-making processes for system acquisition, modernization, sustainment and operations.

3. CBM+ uses sensors, data collection techniques, algorithms, and engineering analysis to provide applicable and effective maintenance requirements.

CBM+ Enables Affordable Life Cycle Maintenance



Evolution

CBM+ Enables Affordable Life Cycle Maintenance



Why Should NAVSEA Implement CBM+?

At NAVSEA, ship maintenance and lifecycle sustainment are critical to the warfare enterprise.

NAVSEA expects to realize the following benefits from CBM+ implementation:– Improved Readiness and Availability of Ships

• Metrics under development • TOC and MTBF are under analysis

– Lower Lifecycle Maintenance Costs• CBM+ prevents high $ failures from occurring• BCAs must indicate that CBM $ over lifecycle pays off

– Achieve Expected Service Life of Ships• The average cost of maintaining a Navy Destroyer over a 35 year lifecycle is over

$65 Million per year, this is in addition to the ~ $2.6 Billion procurement cost for this ship

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Source: GAO Report 12-113 - January 2012 ARLEIGH BURKE DESTROYERS Additional Analysis and Oversight Required to Support the Navy’s Future Surface Combatant Plans



Alignment to NAVSEA’s 2013-2018 Strategic Business Plan

• CBM+ concepts and projects align to each of the Strategic Plan’s Mission Priorities– It’s all about the Ships

• Improving ship maintenance using technology to predict failures• Reinvigorate shipboard preventive maintenance using NAVSEA’s RCM process to weed out

ineffective maintenance tasks and fine tune remaining tasks • Improve warfighting system commonality by standardizing CBM+ top level requirements

across the NAVSEA Enterprise– Technical Excellence and Judiciousness

• Accelerate knowledge transfer by sharing the good and bad about our CBM+ projects• Increase knowledge management and improve maintainer competency through computer

based training courses • Enforce budgetary judiciousness by ensuring that we are getting the most “bang-for-the

buck” from our CBM+ technology investment– Culture of Affordability

• Challenge every maintenance requirement--perform RCM analysis to determine applicability and effectiveness

• Support Ship Characteristics Improvement Board decision making process by performing and thoroughly reviewing BCAs to determine cost benefits before buying technologies

• Maximize commonality across platforms utilizing MIL-STD 3034A and DIDs for RCM and CBM+ in acquisition



Benefits

Improve Readiness and Availability of Assets

Improve equipment health to achieve Expected Service Life (ESL)

Maximize efficiency and reduce life-cycle maintenance costs through data-driven maintenance decisions



BACKUP SLIDES



ESC Goals• Establish CBM+ as a priority within NAVSEA• Implement CBM+ policy across NAVSEA• Determine the status and maturity level of NAVSEA’s existing

CBM+ technologies• Encourage use of proven cost effective CBM+ technologies• Encourage commonality to reduce variations when selecting

CBM+ technologies• Remove barriers to CBM+ implementation• Identify and promulgate best practices while streamlining

redundancies• Incorporate CBM+ in engineering design specifications,

Systems Engineering Plans (SEPs), BCAs, Life Cycle Sustainment Plans (LCSPs), maintenance planning 081 specifications and sustainment KPPs and KSAs within CDDs and CPDs



CBM+ Task Force Actions• The CBM+ Task Force (TF) will:

– Determine the current state of CBM+ technologies being used in the Fleet• Data is being collected from each organization to aid in determining what we have

today and capturing lessons learned

– Determine maturity levels of existing systems– Explore cross enterprise, comprehensive end-to-end systems to take

advantage of cost avoidance opportunities – Review systems in acquisition and modernization to ensure sensors are

being installed and placed appropriately based on RCM analysis and failure modes that are trying to be prevented

– Develop a common CBM+ BCA template for NAVSEA to be used by acquisition and modernization programs

– Develop a common CBM+ LCSP template for NAVSEA to be used by acquisition and modernization programs

– Develop a 081 Maintenance Planning Specification for NAVSEA to be used by acquisition and modernization programs

– Determine what systems could benefit from CBM+ technologies29



CBM+ TF Accomplishments• Charters

– ESC and TF charters have been developed• CBM+ Program Strategic Business Plan (SBP) and Plan of Actions & Milestones (POA&M)

– Aligned to NAVSEA’s SBP and ESC goals• CBM+ Technology Matrix (living document)

– Detailed questionnaire capturing key elements for all NAVSEA CBM+ technologies– Will be used for documenting the current state and identifying gaps and redundancies

• Document reviews completed– JCIDS Manual– SECNAVINST 5000.2F– NAVSEAINST 5000.9A– OPNAVINST 4790.16B

• Document reviews in progress– Systems Engineering Plan (SEP) Guide – Technical Review Manual– SECNAVINST 5400.15C – SECNAV-M 5000.2

• Template development– Draft 081 Maintenance Planning Specification template– Draft LCSP template– Draft BCA template



NAVSEA CBM+ Technology MetricsCBM+ Maturity Levels 1/30/150 - System identified for CBM+ consideration. 138

1- CBM+ Need Identified. RCM or FMEA analysis (relevant failure modes) done. 8

2- Technology concept or CBM application formulated. 35

3 – BCA has been completed that indicates that implementation of a CBM+ technology will lower life cycle maintenance cost.

0

4- CBM+ technology has been validated in a laboratory or relevant environment. 5

5- System or subsystem model or prototype has been demonstrated in a relevant shore based environment.

16

6 - System prototype has been demonstrated in an operational environment. 2

7 - CBM+ technology has been proven to work in its final form and under expected conditions.

32

8 - Actual system installed on platforms, and performing operationally under mission conditions.

124

Unknown 30Grand Total 390



NAVSEA CBM+ Technology MetricsCBM+ Technology Details 1/30/15

Total Number of NAVSEA CBM+ Systems Identified 390HM&E Systems 233Combat Systems 157Different generic sensor types (e.g. pressure switch, pressure transducer, RTD, thermocouple, position indicator, voltage, etc. )

52

Technologies that answered “YES” to the following questions:Are continuous failure probability predictions based on equipment conditions available?

42

Has a business case analysis (BCA) been performed? 117Is there a capability to view ashore the same prognostic, diagnostic and maintenance information seen aboard ship? (i.e. Is data uploaded to a Distance Support Facility?)

133

Do distance support services avoid recurring cost licensing for this technology? (i.e. Government owns data rights to the technology (i.e. software))

145

Does the technology support Wide Area Network (WAN) reduced bandwidth? 114Does analysis performed support an estimation of time to failure if no action is taken? 46Is the diagnostic data used to determine equipment health? 204Is/Has data from this technology being/been used to impact maintenance decisions? 190Is a human machine interface (HMI) used by the crew to display equipment and system health information?

278



Source: Reliability-Centered Maintenance, Nowlan and Heap

Operating age (time T)

Inspection Interval

Re

sist

an

ce t

o f

ailu

re (

Rf) • B (Bearing temperature or vibration begins to increase)

• F (Bearing fails)

DT½(F-P)

•A (New bearing installed)100%

0%

CBM Example

• P (Bearing vibration reaches threshold)



Is a PM Task Applicable?

• A task is applicable if it discovers, prevents, or reduces the impact of a failure mode identified through RCM analysis.



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Is a PM Task Effective?

• A task is effective if it reduces the risk of the occurrence or economic impact of a failure to an acceptable level based on the consequences of failure.

• If the cost of preventive maintenance is less than the cost of repair plus the cost of lost capability, performing the preventive maintenance task is cost effective.

CPM < CR + CLC Distribution Statement A: Approved for Public Release; Distribution Unlimited


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