RCM Made Easy

RCMBlitzTM
RCM Made Simple

Introduction to RCM Blitz
Presented by:
Doug Plucknette
World-Wide RCM Discipline Leader
GPAllied
What would you do with more

free time?
Copyright 2008 Allied Reliability, Inc.
RCMBlitzTM
Welcome to our RCM Blitz!

When it comes to building a complete maintenance
strategy that will achieve and maintain the inherent
designed reliability of an asset, there is no other tool
available that has the success record of traditional RCM.
Doug Plucknette
Reliability Centered Maintenance
Using RCM Blitz
RCMBlitzTM
Specific Benefits of Applying the RCM to

Y
Your
Process
P
Your Company will be able to develop a
complete maintenance strategy for your
equipment that includes clearly written and
precise preventive and predictive
maintenance tasks
Your Company will be able to put into place
failure-finding
g tasks that will reduce the
probability of catastrophic HSE (Health,
Safety, Environmental) failures
RCMBlitzTM
Specific Benefits of Applying the RCM

M th d to
Method
t Y
Your Process,
P
contd
td
Your Company will learn how to reduce MTTR
(Mean Time To Restore) through the use of
Consequence Reduction Tasks
Your Company will be able to determine the
spare parts that need to be stored on site
and the parts that can stored by a vendor
Your Company will learn how to identify where
to apply
pp y the RCM Blitz process
p
based on
Reliability Measures
RCMBlitzTM

M th d to
Method
t Y
Your Process,
P
contd
td
Reduce Emergency/Demand maintenance work
Reduce maintenance costs by reducing
secondary equipment damage
Reduce unit cost of product by lowering
maintenance costs and improving Overall
Equipment
q p
Effectiveness (OEE)
(
)
Increase the understanding of how your
equipment is supposed to work for both
operations
ti
and
d maintenance
i t
people
l
RCMBlitzTM

M th d to
Method
t Y
Your Process,
P
contd
td
Develop a detailed and effective
troubleshooting guide based on actual failure
alarms, effects and symptoms
Develop detailed operations checklists to
ensure proper set-up and operation of
equipment - (What would the reliability of the
airline industry be without checklists?)
Learn how to apply
pp y the RCM process
p
to new
equipment designs
RCMBlitzTM
Why Does the RCM Method Work?

RCM adds the right amount of structure and discipline
to the expert knowledge of your people
The finished product is a complete maintenance
strategy based on predicting, preventing and
eliminating specific Failure Modes
The airline industry has a proven record of reliability
and safety yet their maintenance cost per replacement
value
l is
i lower
l
than
th mostt manufacturing
f t i
maintenance
i t
The big difference is leadership, structure and
discipline
RCMBlitzTM
Section 1 RCM History

RCMBlitzTM

free time?
RCMBlitzTM
The History of RCM

US DOD and United Airlines
Utilities Industry
Manufacturing
Commercial Standards for RCM
SAE J1011
PASS55
RCMBlitzTM
Various Approaches to RCM

Traditional SAE J1011
7 Steps
p
Streamlined
PMO
RCMBlitzTM
Section 4 RCM Maintenance

Strategies
St
ateg es
RCMBlitzTM

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RCMBlitzTM
Maintenance Tasks
The key to ensuring the designed reliability
of y
your process is selecting
g the correct
maintenance task to address a specific
failure mode or cause of failure
RCMBlitzTM
Maintenance Tasks, contd

In RCM we have 5 types of maintenance tasks
1.
2
2.
3.
4
4.
5.
On-condition Maintenance
Preventive Maintenance
Failure Finding
Redesign
Run to Failure
RCMBlitzTM
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
RCMBlitzTM
Traditional Types of On-Condition

M i t
Maintenance
Vibration Analysis
Thermography
g
Ultrasonic Testing
Tribology
g
Non-Destructive Testing
Motor Current Analysis
Process Verification
RCMBlitzTM
Non-Traditional Types of On-Condition

M i t
Maintenance
Human Senses
RCMBlitzTM
How PdM Works Early Identification of

D f t
Defects
RCMBlitzTM
Completing the P-F Curve

RCM Reliability Centered Maintenance
FMEA
Design RCM Blitz
Five Rights of Reliability
S l t Supplier
Select
S
li Agreements
A
t
Requirements Documents
Design Standards
Res
sistance tto Failure
Precision Alignment
Precision Balancing
Installation Standards
Torque Specifications
Precision Tools
Proactive Maintenance/Reliability Tasks
PdM Tasks
Reactive
Maintenance
Installation
P Potential Failure
F Functional
I-P Interval
P-F Interval
Failure
T - Time
The Modified P-F Curve and I-P Interval are intellectual property of Reliability Solutions, Inc. (Patent Pending)
RCMBlitzTM
Preventive Maintenance (PM) Tasks

Preventive maintenance is time based, it is
performed on equipment that has a known
age or useful
f l life
lif
These tasks should be set up to prevent
failures on components that fit age based
failure patterns (A-C)
p
, Scheduled Rework
Scheduled Inspection,
and Scheduled Discard are preventive
maintenance tasks
RCMBlitzTM
Failure Finding Tasks

Scheduled inspections of a hidden function
item, intended to find functional failures that
have already occurred but are not evident to
the operating crew
The objective of a failure finding task is to
ensure adequate availability of a hidden
function
RCMBlitzTM
Redesign
Any change in equipment, process, or
procedures
In order for a redesign to be considered
applicable and effective it must:
Eliminate the failure
Be cost effective
Reduce the conditional probability of failure to an
acceptable level
Change the function of an item from hidden to
evident
RCMBlitzTM
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
consequence reduction strategy
RCMBlitzTM
Consequence Reduction Strategy

When no schedule maintenance is the only
remaining
g strategy,
gy it becomes important to
make sure you have the proper spare parts,
resources and procedures in place to reduce
th consequence off th
the
the failure
f il
RCMBlitzTM
Pulling It All Together

So how is all of this accomplished?
Apply the RCMBlitz process to your equipment!
RCMBlitzTM
Section 5 The RCM Process

RCMBlitzTM

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RCMBlitzTM
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?
RCMBlitzTM
The RCM Process

1. List the Process Functions
2. List the Functional Failures
3. List the Failure Modes and Probability of
Failure
4. Describe the Failure Effects
5. Determine Consequence Category
6. Run the Failure Mode through the RCM
Decision Process
7. Select a Maintenance Task and assess
spare
p
parts
p
RCMBlitzTM
Listing Functions
Function
The normal or characteristic actions of an item,
defined in terms of performance capabilities
Point at which you actually begin your RCM
analysis
Listing the system and component functions is a
key
y step
p in the RCM p
process
The first function we list will be the System
Function or Main Function
The System Function will clearly state what the
intent of the process is, and the performance
standards it is expected
p
to maintain
RCMBlitzTM
Main Function
The Main Function or System Function
The reason the asset or p
process exists including
g
the expectation of the process and performance
standards we need to maintain
Example Main Function
If you were about to analyze a process that made #2
pencils, your main function would be:
1.To
1
T be
b able
bl tto make
k #2 pencils
il att a rate
t off 1200 units
it per
hour, while meeting all quality, safety, health, and
environmental standards
RCMBlitzTM
Main Function, contd

Once you have listed the Main Function and
determined the performance standards, you
y
will move on to list all of the support
functions
RCMBlitzTM
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:
To be capable of shutting down the system in the event
of an emergency
A support function for equipment structure would be:
To be able to support the vessel
RCMBlitzTM
Hidden Functions
Functions that will not be evident to the
operating
g crew under performance of their
normal duties
In 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
RCMBlitzTM
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
RCMBlitzTM
Functional Failure, contd

There may be one or more functional failures
for every
y function
Main Function
1. To be able to make # 2 pencils at a rate of 1200
units per hour while meeting quality,
quality health,
health
safety and Environmental standards
Functional Failure
1. 1. Unable to make #2 pencils at all
1. 2. Unable to make pencils at a rate of 1200 per hr
1 3.
1.
3 U
Unable
bl to
t meett quality
lit standards
t d d
1. 4. Unable to maintain health, safety and
environmental standards
RCMBlitzTM
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
Fuel Pump Bearing (Part)
Seized (Problem)
p
cause))
Fails due to lack of lubrication ((specific
RCMBlitzTM
Failure Modes, contd

When listing Failure Modes you should
remember to include:
All failure modes that have occurred

All dominant failure modes
Failure modes that are likely to occur
Failure modes that have occurred on similar
equipment
RCMBlitzTM

Do Not List:
Failure modes that are highly unlikely to occur!
RCMBlitzTM

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
RCMBlitzTM
Failure Effects
The immediate physical effects of a
functional failure on surrounding
g items and
on the functional capability of the equipment
Failure Effects are the principal determinant
of failure consequences
RCMBlitzTM
Failure Effects, contd

Failure Effect statements should include:
Events that lead up
p to the failure
The first sign of evidence by which the operating
crew will
ill recognize
i the
h failure
f il
has
h occurred
d
All of the secondary effects that resulted from the
failure
Events required to bring the process back to
normal operating condition
RCMBlitzTM
Example Failure Effect Statement

Failure Mode Fuel pump bearing seized due
to lack of lubrication
Failure Effect Statement
Without proper lubrication, the pump bearing will heat up, vibrate
y seize ((events leading
g up
p
and if left to its own devices eventually
to the failure) When the bearing fails the pump shuts down, the
flow switch will alarm the operators when the flow falls below
75 gpm for more than one minute (operators first sign of
evidence)The operator will attempt to restart the pump and it
will again shut down Operator will call maintenance to trouble
shoot, repair and replace (events required to bring process to
normal operating condition)
RCMBlitzTM
The RCM Decision Process

Uses a series of questions to determine:
The consequence
q
category
g y 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
hidden failures
An inspection that reduces the probability of
failure to an acceptable level
A consequence reduction task to reduce MTTR for
run to failure decisions
RCMBlitzTM
Failure Consequences
The first step in the RCM decision process
is to locate the correct category for the
f il
failure
consequence
Each Failure
Fail re Mode will
ill fall into one of these
four categories:
Hidden Failure Consequences

Health, Safety, or Environmental Consequences
Operational Consequences
Non-Operational Consequences
RCMBlitzTM
Hidden Failure Consequences

Consequences that result from the failure of
a Hidden Function
The failure of this device will not be evident
to the operating crew during the performance
of their normal duties
RCMBlitzTM
Hidden Failures
Examples of components with Hidden
Functions:
Emergency Stop Switches

High Level Switches
Relief Valves
Rupture Discs
P
Pressure
S it h
Switches
Redundant Devices
RCMBlitzTM
Health, Safety, and Environmental

Consequences
Consequences resulting from a functional
failure that could have a direct adverse effect
on health, safety, or environment
RCMBlitzTM
Operational Consequences
The economic consequences of a failure that
interferes with the planned use of operating
g
equipment
Examples of Operational Consequences:
Cost of lost production

C t off maintenance
Cost
i t
Cost of replacement parts
Cost of waste
RCMBlitzTM
Non-Operational Consequences
The economic consequences of a failure that
does not affect safety
y or the operational
capability of the equipment
Typically these are non-significant items that
have no hidden functions
RCMBlitzTM
The RCM Decision Process

Once the correct consequence category has
been selected, RCM then asks a series of
questions to identify the correct maintenance
task
RCMBlitzTM
Spare Parts
No maintenance strategy is complete without
assessing
g 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
RCMBlitzTM
Section 6 RCM Implementation

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RCMBlitzTM
RCM Implementation
Your RCM analysis is not complete until all
tasks have been implemented
Each Task should be assigned
g
to a specific
p
person and assigned a due date
Implementation can be tracked in the
database
RCMBlitzTM
RCM Management Review Meetings

Communication is critical to successful
implementation
Report implementation progress
Develop future path for critical assets
Communicate
C
i t success
RCMBlitzTM
Barriers to Successful Implementation

Failure to prioritize tasks
Unrealistic due dates
Analysis/Task ownership
Resource allocation
RCMBlitzTM
Questions?
rsmith@gpallied.com
ith@
lli d

RCM Made Easy

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RCMBlitzTM

RCM Made Simple

What would you do with more

Copyright 2008 Allied Reliability, Inc.

Welcome to our RCM Blitz!

Copyright 2008 Allied Reliability, Inc.

Specific Benefits of Applying the RCM to

Specific Benefits of Applying the RCM

Copyright 2008 Allied Reliability, Inc.

Specific Benefits of Applying the RCM

Copyright 2008 Allied Reliability, Inc.

Specific Benefits of Applying the RCM

Copyright 2008 Allied Reliability, Inc.

Why Does the RCM Method Work?

Copyright 2008 Allied Reliability, Inc.

Section 1 RCM History

What would you do with more

Copyright 2008 Allied Reliability, Inc.

The History of RCM

Copyright 2008 Allied Reliability, Inc.

Various Approaches to RCM

Copyright 2008 Allied Reliability, Inc.

Section 4 RCM Maintenance

What would you do with more

Copyright 2008 Allied Reliability, Inc.

Copyright 2008 Allied Reliability, Inc.

Maintenance Tasks, contd

Copyright 2008 Allied Reliability, Inc.

Copyright 2008 Allied Reliability, Inc.

Traditional Types of On-Condition

Copyright 2008 Allied Reliability, Inc.

Non-Traditional Types of On-Condition

Copyright 2008 Allied Reliability, Inc.

How PdM Works Early Identification of

Copyright 2008 Allied Reliability, Inc.

Completing the P-F Curve

Proactive Maintenance/Reliability Tasks

Copyright 2008 Allied Reliability, Inc.

Preventive Maintenance (PM) Tasks

Copyright 2008 Allied Reliability, Inc.

Failure Finding Tasks

Copyright 2008 Allied Reliability, Inc.

Copyright 2008 Allied Reliability, Inc.

Consequence Reduction Strategy

Copyright 2008 Allied Reliability, Inc.

Pulling It All Together

Copyright 2008 Allied Reliability, Inc.

Section 5 The RCM Process

What would you do with more

Copyright 2008 Allied Reliability, Inc.

The 7 Steps of Reliability Centered Maintenance

Copyright 2008 Allied Reliability, Inc.

The RCM Process

Copyright 2008 Allied Reliability, Inc.

Main Function, contd

Copyright 2008 Allied Reliability, Inc.

Copyright 2008 Allied Reliability, Inc.

Copyright 2008 Allied Reliability, Inc.

Copyright 2008 Allied Reliability, Inc.

Functional Failure, contd

Copyright 2008 Allied Reliability, Inc.

Failure Modes, contd

All failure modes that have occurred