Reliability Centered Maintenance - RCM

An Overview of the Process

Presented By:
Jeff Banks
Research Engineer
The Applied Research Laboratory at
The Pennsylvania State University
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 Reliability Centered
Maintenance - RCM

What is Reliability Centered Maintenance?

It is not:
Hardware or Software
A Type of Maintenance
A Product that is Purchased

It is a systematic process and methodology for

determining the most effective and efficient
maintenance management plan for a specific
platform, system or component.
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Condition Based Maintenance Plus
DoD Guidebook, May 2008

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Air Force RCM

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 Air Force
RCM and CBM+ Guidance

Reference: Robert Riegert, HAF/A4ID, 1 February 2012, Version 1.0 5

 Air Force
RCM and CBM+ Guidance

Reference: Robert Riegert, HAF/A4ID, 1 February 2012, Version 1.0 6

 Air Force
RCM and CBM+ Guidance

Reference: Robert Riegert, HAF/A4ID, 1 February 2012, Version 1.0 7

 AFI 21-104 (11 December 2007): Selective
Management of Selected Gas Turbine
Engines
RCM is an integral part of engine life management for all
engines covered by this instruction.
RCM is an analytical process to determine the appropriate failure
management strategies, including preventive maintenance
requirements and other actions that are warranted to ensure safe
operations while balancing readiness and costs.

Engine Trending and Diagnostics (ET&D) is a program

integrating hardware, software, technical documents, training,
maintenance, and diagnostic/prognostic processes to
quantify and monitor/manage engine health.

Effective use of ET&D can reduce engine flight safety risk,

improve reliability, and optimize life cycle costs. 8
 References for DoD RCM
There are two fundamental documents that provide the
material for conducting RCM for DoD.

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 Definition of RCM Using SAE
JA1011 and JA1012 Standards

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 Reasons for Initiating RCM
Activities that could trigger the performance of an RCM analysis include but are not
limited to:

The system design has stabilized and the system is entering testing (Milestone
B).
A significant design change has occurred (an Engineering Change Proposal
(ECP) has been executed), and no RCM analysis was previously performed.
Unexpected failure rates have been identified (this analysis may be limited to
only those systems that are exhibiting excessive or costly failures.
The systems operating context has changed (for example: the system is being
exposed to a new climate, the system encounters a new thread (IEDs), etc.).
Guiding documentation directs the conduct of time-based analyses, or at given
stages of the system life-cycle.

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The Major Elements of the Basic
RCM Process
RCM Establishment and Planning
Analysis:
Define the function and functional failures of a
specific platform, system or component.
Then conduct a Failure Modes and Effects
Analysis
Identify the failure consequences
Determine maintenance tasks and intervals.
Analysis Audit
Implementation

Sustaining the RCM Program:

RCM is a Living Program
Implement a RCM management, training,
benchmarking, and review process to provide
feedback and measurement of progress
toward asset management goals
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 RCM Program Establishment
and Planning
Identify Planning Team
1.1 Determine Scope of Analysis
Identify Planning Team
Identify persons to support initial RCM Program
Identify System Boundaries
planning Determine Level of Analysis
Determine Extent of Analysis
1.2
Determine Scope Of Analysis
Extent of the RCM analysis effort to be applied to
Identify Ground Rules and Assumptions
meet program objectives Standard operating procedures
Data sources
1.3 Analytical methods
Identify Ground Rules and Assumptions
Identify the analysis enablers and constraints Cost-benefit analysis methods
Approaches to specific types of problems
Default values (e.g., labor rates, equipment usage
1.4
rates, common material costs)
Determine Manpower Considerations Acceptable probabilities of failure for certain failure
Consider the manpower commitment, skills and
organization to support the RCM program
modes based on severity
Determine Manpower Considerations
1.5
1.6
Consider use of Modeling and Simulation (M&S)
Identify Training and Certification Requirements
Identify the training and/or certification
1.7
Determine Data Sources Identify Training and Certification
M&S can be applied throughout life-cycle to Identify data requirements and source, crucial
augment RCM program
expectations of each role supporting the RCM
program
to conducting the RCM analysis Consider use of Modeling and Simulation
Determine Data Sources
1.8
Identify Funding Requirements
What are the costs inherent in establishing and
Identify Funding Requirements
sustaining an RCM program Involves identifying the costs to establish and sustain
the RCM program.
1.9 Training costs, team member travel costs, facility and
Develop Sustainment Plan
Identify how RCM program will be sustained material costs in support of analysis
throughout the equipment life cycle
Develop Sustainment Plan
Living Process 13
 Important Factor: Participation
RCM Lead/Champion: Directs the planning efforts, analysis preparations, analysis
performance, and overall program execution
RCM Facilitator: A highly skilled and experienced RCM professional, who supports the
RCM Lead in preparing for an analysis, and leads an analysis team through the actual
conduct of an analysis
Support Personnel:
Engineering: Crucial to data collection and analysis efforts, and a key member in
performing the RCM analysis of the platform/system
Cost/Budget Analysts: Performs high-level cost benefit analyses of recommendation
resulting from an analysis, and assists in budgeting for program execution
Logistician: Another key member in supporting data collection and analysis.
Supports RCM analysis by providing system/supply chain expertise, and operational
context
Operators and Maintainers: The most crucial member of the RCM analysis team. They
have a full understanding of operational context, and fill in data gaps that are not available
under current Information technology (IT) capabilities with practical experience and
expertise.
In operating and maintaining the analyzed system, Operators and Maintainers have a full
understanding of the current support philosophy, and provide key insight into the impact of
any recommended changes.
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 Steps for the Analysis Process:
Information and Decision
1. Identify System Functions: What does the user need
the system to do in its current operating context?
2. Identify Functional Failures: In what way can the
system fail (or fail to fulfill its function)?
3. Identify the Failure Modes: What causes the failures?
4. Identify the Failure Effects: What happens when
failures occur and what are the symptoms of failure?
5. Identify Failure Consequences: How and why does the
failure matter.
Frequency of occurrence
Severity of the failure mode
6. Determine Maintenance Tasks and Intervals: Can the
failure be predicted or prevented?
7. Identify Other Logical Actions: What can be done if the
failure cannot be predicted or prevented?
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Example of Standard FMEA
(RCM Required)

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 Example FMECA Format
(Not RCM Required)

Criticality information provides additional

context for decision making. 17
 Example FMECA+ Format
(Not RCM Required)

Additional sensor information provides organized

details for determining the on-condition tasks
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 FMECA Example: Aircraft Fuel
System
Precursors or Sensors and sensor
symptoms prior to full placement
functional failure requirements

Health management
processing
techniques for
diagnosing and
prognosing
symptoms 19
 Introduction to the Failure
Consequences (Decision Process)

The consequences of every failure mode shall be formally

categorized.
Hidden verse Evident Failure Modes

Safety and Environmental (1st priority) and Economic (2nd

priority) consequences.

Operational (1st priority) and Non-Operational (2nd

priority) consequences.

Assessment of failure consequences shall be carried out

as if no specific task is currently being done to anticipate,
prevent or detect the failure.
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Reference: SAE JA1011 Standard
 Classical RCM Decision Diagram
Process (Example Simple Version)
SAE J1011 standard
requires that the decision
process assess the safety
and environmental
consequences of failure.

This decision diagram does

not so that it is not a valid
SAE approach.
CBM

Preventative

Replace Part
Operating Equipment Asset Management by John Mitchell 21
SAE JA1012A Decision Diagram

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 Scheduled - Failure Management
Policies: On-Condition Tasks
On-Condition Tasks (Predictive or Condition Based Maintenance) can be
implemented for a specific failure mode for maintenance if:
There exists a clearly defined potential failure as well as a failure development
period as described by the P-F curve.
It must be possible to do the on-condition task at intervals less than the P-F interval.
The shortest time between the discovery of the potential failure and the
occurrence of the functional failure must be long enough to take action to avoid,
eliminate or minimize the consequences of the failure mode.

On-Condition Tasks:
items that are inspected
are left in service, on-
condition that the
considered failure mode is
unlikely to occur before the
next check.

Reference: SAE JA1012 Standard 23

 P-F Interval

The interval between the occurrence of a

potential failure and its decay into a
functional failure
Point where Vibration
failure starts Oil
Analysis Analysis
to occur Detection Temperature
Detection
Detection Audible
Noise
Detection
Condition

If the P-F interval is too short,

PT&I technology may not be effective.

Time Functional
Failure
Reference: Reliability-centred Maintenace , by John Moubray 24
 Scheduled - Failure Management Policies:
Scheduled Restoration and Discard Tasks

Scheduled Restoration and Discard Tasks (Preventative Maintenance) can be

implemented for a specific failure mode for maintenance if:

There should be a clearly defined age at which there is an increase in the

conditional probability of the failure mode occurring.

A sufficiently large proportion of the occurrences of this failure mode shall occur
after this age to reduce the probability of premature failure.

Relationship between Age and Failure: The failure

management process should take into account the
conditional probability of some failure modes that will
increase with age, decrease with age or not change with
age.
In general, these patterns are associated with direct
wear, fatigue, corrosion, oxidation and evaporation.

Reference: SAE JA1012 Standard 25

 Conditional Probability of Failure

Type A - Constant or gradually increasing failure

probability, followed by a pronounced wear-out
region. An age limit may be desirable. (Typical of
reciprocating engines.)

Type B - Infant mortality, followed by a constant or

slowly increasing failure probability. (Typical of
electronic equipment.)

Type C - Low failure probability when the item is

new or just overhauled, followed by a quick
increase to a relatively constant level.

Type D - Relatively constant probability of failure

at all ages.

Type E* - Bathtub curve; i.e., infant mortality

followed by a constant or gradually increasing
failure probability and then a pronounced wear-out
region. An age limit may be desirable, provided a
large number of units survive to the age where
wear-out begins.

Type F - Gradually increasing failure probability,

but no identifiable wear-out age. Age limit usually
not applicable. (Typical of turbine engines.)

A and E characteristic of simple systems

B, C, D and F characteristic of complex systems with a 26
dominant failure mode
 Scheduled - Failure Management
Policies: Failure Finding Tasks

Failure Finding Tasks are conducted for hidden

failure modes, where it may not be evident that an
item has failed.
The intent is to reduce the probability of the occurrence of a multiple
failure involving the protection device (i.e. fire extinguishing system)
and protected system (i.e. vehicle).
It should be taken into consideration that the failure finding task and
associated interval may leave hidden function in a failed state (i.e.
repeated testing of the fire extinguishing system over a period of time
may deplete the level so that it no longer functions).

Combination Tasks may be implemented when a single

task does not mitigate or manage the impact of safety and
environmental failure modes. 27
 Failure Management Policies: One
Time Changes and Run to Failure

Redesign: are recommended to No Scheduled Maintenance: There

reduce the consequences of a are cases in which failures may
failure or resolve problems that occur that have no significant impact
are identified during the RCM on the function of the system (i.e.
analysis. run to failure).

They are unique activities that It is more economical to allow the

include:
Design changes
Training program changes
Operating procedures changes
Emergency procedures changes
Technical manuals changes
The collection of additional data
No scheduled maintenance
failure to occur than to mitigate it.
Run to failure will only be employed
when an appropriate scheduled task,
or cost effective proactive task
cannot be identified, and the
occurrence of the failure does not
have a safety or environmental
impact.

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 Analysis Audit

The Analysis Audit ensures that completed analyses are:

Technically sound
Follow the guidance and processes of the owning organization
Provide recommendations with defensible benefits
Support Perform Management Review and the implementation.

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 Implementation
The most important part of the RCM process is implementing the
results of the analysis.
Need to have a capable RCM lead/champion who can
socialize the results of the RCM analysis with the PM.
The RCM Lead should work with the PM to request, allocate,
and prioritize available funding to meet program needs based
on the RCM results.
4.1
4.2
Perform
Publish Finalized Analysis
Analysis Audit Management Review Recommendation
Approved?
Yes Key document collected
completed Management
and published for use/
approves or denies
reference
recommendations

No

Record
Disapproval in
Audit Package
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 Sustaining the RCM Program
RCM is a Living Process that requires
periodic review and reassessment to
validate the analysis results and
decisions.

Two Realities about RCM and

Maintenance:
The maintenance system, policies,
personnel and technology will evolve
and change.

The analysis will not be perfect the

first time through the process but it
should be noted where the program
provided benefits. 31
 Sustaining the RCM Program
Original RCM groups should review their results to consider the
following questions:
Has the operating context of the equipment changed?
Have the performance expectations of the equipment changed?
Have any failure modes occurred or effects changed?
Should the failure consequences be reconsidered for any reason?
Are the maintenance tasks selected in the decision process still
valid and worth conducting? Should the frequency be changed?
Is there a better proactive technique to one selected for the failure
mode?
Should a maintenance task be conducted by someone different than
the person selected?
Has the equipment been modified to change any functions or failure
modes?

Reliability-centred Maintenance, By John Moubray 32

 RCM Summary
Make sure that the people who know the systems, participate in the analysis:
Process can be conducted faster and is more effective and everyone will
learn more.
Inexperienced personnel will also gain a tremendous amount of valuable
information when they participate but only if the knowledgeable people
participate.

Having a trained facilitator lead the process:

Provides a guide for getting the greatest benefit from the analysis.

The RCM process is only as effective as what each individual contributes.

The more effort put in, the better the results, which will provide confidence in
the implementation.

The RCM process is a living methodology that must be revisited periodically for
the most effective implementation.

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