This presentation demystifies the common misconceptions about Reliability Centered Maintenance (RCM). Sadly, it is often wrongly believed that RCM takes too long to perform, or it is too expensive, or it is too complicated. This just isn’t so. These misunderstandings about RCM stem from key misconceptions of the RCM process: 1. RCM seeks to analyze every Failure Mode; 2. RCM is too time and resource intensive; 3. RCM is just about deriving proactive maintenance; 4. RCM, Failure Modes and Effects Analysis (FMEA), and Failure Modes, Effects, and Criticality Analysis (FMECA) are independent process; 5. Condition Based Maintenance (CBM) and RCM are independent processes; 6. Reading a book or attending an introductory course provides the expertise required to implement RCM. This presentation debunks these misconceptions and sets forth just how robust, powerful, and uncomplicated the RCM process really is.

1. Demystifying the Common
Misconceptions
about
Reliability Centered Maintenance
By Nancy Regan
NancyRegan@RCMTrainingOnline.com

2. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

3. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

4. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

5. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

6. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

7. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

8. Copyright © The Force Inc. 2018 All Rights Reserved
Together, Let’s Discover…
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive

9. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
RCM is a zero-based process used to identify
the Failure Management Strategies that are
required to ensure an asset meets its
missions requirements in its operational
environment in the most safe and cost
effective manner
Reliability Centered Maintenance

10. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
RCM is a zero-based process used to identify
the Failure Management Strategies that are
required to ensure an asset meets its
missions requirements in its operational
environment in the most safe and cost
effective manner
Reliability Centered Maintenance

11. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
RCM is a zero-based process used to identify
the Failure Management Strategies that are
required to ensure an asset meets its
missions requirements in its operational
environment in the most safe and cost
effective manner
Reliability Centered Maintenance
What specifically causes a
Functional Failure
We manage assets at the
Failure Mode level

12. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
RCM is a zero-based process used to identify
the Failure Management Strategies that are
required to ensure an asset meets its
missions requirements in its operational
environment in the most safe and cost
effective manner
Reliability Centered Maintenance
A story of what would happen if
we did nothing to predict, prevent,
or manage the Failure Mode.

13. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
RCM is a zero-based process used to identify
the Failure Management Strategies that are
required to ensure an asset meets its
missions requirements in its operational
environment in the most safe and cost
effective manner
Reliability Centered Maintenance
Safety
Environmental
Operational
Non-Operational

14. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
RCM is a zero-based process used to identify
the Failure Management Strategies that are
required to ensure an asset meets its
missions requirements in its operational
environment in the most safe and cost
effective manner
Reliability Centered Maintenance
Stay tuned!

15. Copyright © The Force Inc. 2018 All Rights Reserved
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive
FMEA: Failure Modes and Effects Analysis
FMECA: Failure Modes, Effects, and Criticality Analysis
Misconception #1: FMEA, FMECA, and RCM are separate processes

16. Copyright © The Force Inc. 2018 All Rights Reserved
FMEA: Failure Modes and Effects Analysis
FMECA: Failure Modes, Effects, and Criticality Analysis
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
Steps 1-4: FMEA
Failure Modes and
Effects Analysis
Steps 1-5: FMECA
Failure Modes, Effects,
and Criticality Analysis
Misconception #1: FMEA, FMECA, and RCM are separate processes

17. Copyright © The Force Inc. 2018 All Rights Reserved
Misconception #2:
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive
CBM and RCM are separate processes
CBM: Condition Based Maintenance

18. Copyright © The Force Inc. 2018 All Rights Reserved
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
Misconception #2: CBM and RCM are separate processes
CBM: Condition Based Maintenance

19. Copyright © The Force Inc. 2018 All Rights Reserved
What Constitutes Proactive Maintenance in the Context of RCM?
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance (CBM)

20. Copyright © The Force Inc. 2018 All Rights Reserved
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance (CBM)
What Constitutes Proactive Maintenance in the Context of RCM?

21. Copyright © The Force Inc. 2018 All Rights Reserved
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
(Overhaul)
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance (CBM)
What Constitutes Proactive Maintenance in the Context of RCM?

22. Copyright © The Force Inc. 2018 All Rights Reserved
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
(Overhaul)
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance (CBM)
What Constitutes Proactive Maintenance in the Context of RCM?

23. Copyright © The Force Inc. 2018 All Rights Reserved
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
(Overhaul)
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance (CBM)
What Constitutes Proactive Maintenance in the Context of RCM?

24. Copyright © The Force Inc. 2018 All Rights Reserved
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
(Overhaul)
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance
(CBM)
What Constitutes Proactive Maintenance in the Context of RCM?
Synonyms

25. Copyright © The Force Inc. 2018 All Rights Reserved
PROACTIVE
MAINTENANCE
Preventive
Maintenance
Scheduled
Restoration
(Overhaul)
Scheduled
Replacement
On-Condition
Maintenance
Predictive Maintenance
Condition Based Maintenance
(CBM)
What Constitutes Proactive Maintenance in the Context of RCM?
Synonyms
RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
Step 6: Includes CBM
Condition Based Maintenance
So if you’re doing RCM, you are
already considering
Condition Based Maintenance

26. Copyright © The Force Inc. 2018 All Rights Reserved
Misconception #3:
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive
RCM only produces a Proactive Maintenance Plan

27. Copyright © The Force Inc. 2018 All Rights Reserved
RCM is NOT just about maintenance!

28. Copyright © The Force Inc. 2018 All Rights Reserved
Elements That Influence a System
Proactive Maintenance
Operating
Procedures
Issues specific to
your organization
Technical
Publications
Training Programs Equipment
Design
Operational Tempo
and Environment
Supply Issues
System

29. Copyright © The Force Inc. 2018 All Rights Reserved
Elements That Influence a System
Your
Body
Exercise
Mindfulness
Recreation
Habits
Proper sleep
Proper Medical
AttentionSelf-
Improvement
Nutrition

30. Copyright © The Force Inc. 2018 All Rights Reserved
Elements That Influence a System
Proactive Maintenance
Operating
Procedures
Issues specific to
your organization
Technical
Publications
Training Programs Equipment
Design
Operational Tempo
and Environment
Supply Issues
System

31. Copyright © The Force Inc. 2018 All Rights Reserved
Potential Products of an RCM Analysis
Development of the most safe, cost effective,
and technically defensible
Proactive Maintenance Plan
New/Modifications
to Operating
Procedures
Solutions specific
to your
organization
Updates/Additions
to Technical
Publications
New/Modifications
to Training
Programs
Equipment
Redesigns
Troubleshooting
Procedures
Supply Changes
RCM
Can Yield

32. Copyright © The Force Inc. 2018 All Rights Reserved
Potential Products of an RCM Analysis
Development of the most safe, cost effective,
and technically defensible
Proactive Maintenance Plan
New/Modifications
to Operating
Procedures
Solutions specific
to your
organization
Updates/Additions
to Technical
Publications
New/Modifications
to Training
Programs
Equipment
Redesigns
Troubleshooting
Procedures
Supply Changes
Default
Strategies

33. Copyright © The Force Inc. 2018 All Rights Reserved
Potential Products of an RCM Analysis
Proactive Maintenance
New/Modifications
to Operating
Procedures
Solutions specific
to your
organization
Updates/Additions
to Technical
Publications
New/Modifications
to Training
Programs
Equipment
Redesigns
Troubleshooting
Procedures
Supply Changes
Failure
Management
Strategies
RCM is NOT just
about maintenance!

34. Copyright © The Force Inc. 2018 All Rights Reserved
Misconception #4:
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive
RCM takes way too long, is too complex, and is too expensive
1. RCM not carried out properly due to lack of proper training
 Failure Modes written at way too low a level

35. Copyright © The Force Inc. 2018 All Rights Reserved
A properly written Failure Mode puts you on the
right road and sends you in the right direction.
Failure Modes Often Written at Way Too Low Level
GOAL: Proactive Maintenance Plan

36. Copyright © The Force Inc. 2018 All Rights Reserved
Diesel engine fails
Engine oil
deteriorates due to
normal use
Engine oil diminishes
due to normal use
Cooling fan drive belt
wears due to normal
use
Starter motor fails
Change the engine oil
every 6 months.
Check engine oil level
prior to use.
Visually inspect
cooling fan drive belt
every 500 operating
hours.
No scheduled
maintenance
What specifically
causes the diesel
engine to fail?
How detailed should Failure Modes be written?
GOAL:
Proactive Maintenance Plan

37. Copyright © The Force Inc. 2018 All Rights Reserved
How detailed should Failure Modes be written?
Electrical
connection
s loosen
Armature
insulation
breaks
down
Solenoid fails
Starter
motor fails
Brushes wear
GOAL:
Proactive Maintenance Plan

38. Copyright © The Force Inc. 2018 All Rights Reserved
How detailed should Failure Modes be written?
Electrical
connection
s loosen
Armature
insulation
breaks
down
Solenoid fails
Starter
motor fails
Brushes wear
GOAL:
Proactive Maintenance Plan

39. Copyright © The Force Inc. 2018 All Rights Reserved
How detailed should Failure Modes be written?
Starter motor fails
No scheduled
maintenance
Electrical
connection
s loosen
Armature
insulation
breaks
down
Solenoid fails
Starter
motor fails
Brushes wear
Coil burns out …and so on…Plunger sticks
GOAL:
Proactive Maintenance Plan

40. Copyright © The Force Inc. 2018 All Rights Reserved
Misconception #4:
Brief
overview
of the
RCM
Process
Demystify Four
Common
Misconceptions
about RCM
1. FMEA,
FMECA, and
RCM are
separate
processes
2. CBM and
RCM are
separate
processes
3. RCM only
produces a
Proactive
Maintenance
Plan
4. RCM takes
way too long,
is too complex,
and is too
expensive
RCM takes way too long, is too complex, and is too expensive
1. RCM not carried out properly due to lack of proper training
 Failure Modes written at way too low a level

41. Video on most important Reliability Fundamental
GO TO: www.RCMTrainingOnline.com/ASQ/fundamental
Nancy Regan
NancyRegan@RCMTrainingOnline.com
256-541-4806
THANK YOU!