This presentation outlines the goals of a Reliability Centered Maintenance (RCM) analysis. It debunks the top misconceptions about RCM. And it poses and answers the top four questions about RCM most people don’t know to ask.

1. Is Reliability Centered Maintenance (RCM)
Right For You?
Arm yourself with the right information to decide!
By Nancy Regan
Get your FREE RCM Training Video at:
https://RCMTrainingOnline.com/mylml/lml-consult

2. Agenda
 What True RCM really is
 Debunk the top four misconceptions about RCM
 Pose and answer the top four questions about RCM you
may not have known to ask
 Goals that can be achieved using RCM

3. True RCM

4. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner

5. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner
“Reliability”
VS
Design
Capability
Required
Performance

6. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner

7. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner
We manage assets at the
Failure Mode level.
Failure Mode:
What specifically causes
a Functional Failure
We proactively identify what could cause each
Functional Failure, and then we use the remaining four
steps of the RCM process to figure out what (if anything
at all) we should do to manage it.

8. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner
A story of what would happen if we
did nothing to predict, prevent, or
manage each Failure Mode

9. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner
Safety
Environmental
Operational
Non-Operational

10. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner

11. Reliability Centered Maintenance (RCM)
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 mission
requirements in its operational
environment in the most safe and
cost effective manner

12. Debunking the Top Four
Misconceptions about RCM

13. Misconception #1
RCM is too complex and too time and resource intensive
 People complicate it when they don’t apply it correctly
1. “Every single Failure Mode” is listed in the analysis
2. Failure Modes are written at too low a level

14.  People complicate it when they don’t apply it correctly
1. “Every single Failure Mode” is listed in the analysis
1. Happened before
2. Haven’t happened but are real possibilities
3. Unlikely to occur but have severe consequences
4. Currently managed via proactive maintenance
Include Failure Modes
that have:
Misconception #1
RCM is too complex and too time and resource intensive

15.  People complicate it when they don’t apply it correctly
1. “Every single Failure Mode” is listed in the analysis
2. Failure Modes are written at too low a level
Misconception #1
RCM is too complex and too time and resource intensive

16. RCM Process
1. Functions
2. Functional Failures
3. Failure Modes
4. Failure Effects
5. Failure Consequences
6. Proactive Maintenance and Intervals
7. Default Strategies
 Level of analysis (level of detail)
 Depends entirely on the goal of your RCM analysis
Failure Modes are written at too low a level
GOAL: Proactive Maintenance Plan

17. How detailed should Failure Modes be written?
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?

18. How detailed should Failure Modes be written?
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?
GOAL:
Proactive Maintenance Plan

19. Starter motor
fails
No scheduled
maintenance
Electrical
connection
loosens
Armature
insulation
breaks down
Solenoid
fails
Starter motor
fails
Brushes
wear
What specifically
causes the starter
motor to fail?
How detailed should Failure Modes be written?

20. Starter motor
fails
No scheduled
maintenance
Electrical
connection
loosens
Armature
insulation
breaks down
Solenoid
fails
Starter motor
fails
Brushes
wear
What specifically
causes the starter
motor to fail?
How detailed should Failure Modes be written?
Coil burns
out
And so on…
Plunger
sticks
What specifically
causes the
solenoid to fail?

21. Misconception #2

22. Misconception #2
RCM, FMEA, and FMECA are Independent Processes
Failure Modes and Effects Analysis (FMEA)
Failure Modes, Effects, and Criticality Analysis (FMECA)
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
Steps 1-5
FMECA
When RCM is
performed, the
requirement for a
FMEA and FMECA
is largely satisfied.

23. Misconception #3

24. 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
Analysis
Misconception #3
RCM and CBM are Independent Processes
Condition Based Maintenance (CBM)
CBM
is accomplished
when RCM is
applied.

25. Misconceptions #2 and #3
RCM, FMEA, FMECA, and CBM are Independent Processes
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
Steps 1-5
FMECA
Step 6 Includes
CBM Analysis

26. Misconception #4

27. Misconception #4
You must have comprehensive “historical data” in
order to carry out RCM
 RCM questions require specific and detailed
answers
 Generally, the kind of data that organizations
collect isn’t sufficient to answer all the questions
in the RCM process
OEM
FACILITATOR
Maintainer
Systems Engineer
Planner
Electrician
Other Expert
Operator

28. Player Average RBI HR
Smith .204 21 6
Historical Data is Often Like Batting Data
Batting Data

29. Example: Bearing Failure Data
▪ 50 bearings were replaced last year.
► Can conclude that there is an issue with the bearing
► What specifically caused the bearing failures is often not discernable
based on the data alone.
Historical Data is Often Like Batting Data

30. Misconception #4
You must have comprehensive “historical data” in
order to carry out RCM
 RCM questions require specific and detailed
answers
 Generally, the kind of data that organizations
collect isn’t sufficient to answer all the questions
in the RCM process
 Data is often incomplete and requires further
explanation
 Real-world experience and expertise of RCM Working
Group members augment historical data
OEM
FACILITATOR
Maintainer
Systems Engineer
Planner
Electrician
Other Expert
Operator

31. The Top Three Questions
About RCM You May Not
Have Known to Ask

32. Question #1
Does RCM produce more than just a scheduled
maintenance plan?
 RCM goes way beyond maintenance

33. 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

34. 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
Potential Products of an
RCM Analysis

35. Question #2

36. Question #2
Can the information included in an RCM Analysis be
used for other purposes?
 Information from FMEA can be used to develop more detailed
troubleshooting procedures
 RCM Analysis formally records the knowledge and experience of
equipment expert (“tribal knowledge”)

37. Question #3

38. Question #3
At what point in an asset’s lifecycle should RCM be
applied?
 As early in an asset’s lifecycle as possible – beginning with the
design stage
 But, RCM can be successfully applied at any stage in an asset’s
lifecycle
 There are many active and successful legacy RCM programs across the
world – many initiated decades after the system was fielded

39. Goals that can be
Achieved Using RCM

40. Where you may be now
- Safety and Environmental issues
- Increased costs
- Unnecessary Downtime
- Lost Production
- Missed “missions”
Where you may be now HEADACHES!
Ask your
equipment to
do something
that it can’t
Do
unnecessary
maintenance
Not doing the
RIGHT
maintenance
Chronic
Equipment
Failure
Lack of/poor
Operating and
Training
Procedures

41. Where you may be now
- Safety and Environmental issues
- Increased costs
- Unnecessary Downtime
- Lost Production
- Missed “missions”
Where you
may be now
Expect your
equipment
to do
something
that it can’t
Do
unnecessary
maintenance
Not doing
the RIGHT
maintenance
Chronic
Equipment
Failure
Lack of/poor
Operating
and Training
Procedures
Write Functions to “define”
what we want: RELIABILITY
Identify
Failure
Modes
Use the rest of the RCM process
to formulate solutions
(That is…figure out what actions
we need to take to achieve the
“Reliability” we want).
Perform RCM
We
manage
assets at
the Failure
Mode level

42. RCM Goals
Write Functions to “define”
what we want: RELIABILITY
Identify
Failure
Modes
Use the rest of the RCM process
to formulate solutions
(That is…figure out what actions
we need to take to achieve the
“Reliability” we want).
Perform RCM
We
manage
assets at
the Failure
Mode level
By doing RCM, we get:
 Level of Safety and Environmental
Integrity that we define
 “Optimize” maintenance costs
 Eliminate unnecessary downtime
 Meet our production goals/missions
 Memorialize expertise of equipment
experts
 And so much more…

43. RCM Goals
Write Functions to “define”
what we want: RELIABILITY
Identify
Failure
Modes
Use the rest of the RCM process
to formulate solutions
(That is…figure out what actions
we need to take to achieve the
“Reliability” we want).
Perform RCM
We
manage
assets at
the Failure
Mode level
By doing RCM, we get:
 Level of Safety and Environmental
Integrity that we define
 “Optimize” maintenance costs
 Eliminate unnecessary downtime
 Meet our production goals/missions
 Memorialize expertise of equipment
experts
 And so much more…
Is RCM right for you?

44. Nancy Regan
NancyRegan@RCMTrainingOnline.com
Questions?
Get your FREE RCM Training Video at:
https://RCMTrainingOnline.com/mylml/lml-consult