This document provides an overview of Reliability Centered Maintenance (RCM) and how to implement it successfully. It discusses the objectives of RCM, which are to optimize asset performance and utilization of resources. The key steps are: selecting critical assets, performing a Failure Mode and Effects Analysis to identify effective tasks, addressing challenges, and using tools like the 7 questions framework. Implementing an RCM program requires establishing roles, goals, selecting systems for analysis, describing functions and standards, identifying failure modes and effects, assessing consequences, and determining predictive, preventative or other maintenance tasks. The overall aims are improving equipment effectiveness, reliability and minimizing costs over an asset's lifecycle.

1. Selamat Datang Ke-
Reliability Centered Maintenance
(RCM)
Successful Implementation
at your Plant.
Towards Zero Equipment Failures
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2. Reliability Centered Maintenance is
a methodology used to determine
what must be done to ensure
that any physical asset
continues to do what its users
wanted it to do in its present
operating context.”
• Set of PM tasks generated on the
basis of a systematic evaluation.
• Each PM task be related to a failure
mode
• Best available decision strategy for
PM optimization for effective and
efficient maintenance tasks.
It’s more of a method of
analyzing breakdowns of
the Failure modes
• Moving away from
Traditional
Maintenance Mindset
What makes RCM is different
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3. Objectives of this Session
How to integrate RCM strategies with your current maintenance strategies
Physical assets are capital intensive must be operating
optimally increasing asset performance and how to
utilize the resources that are usually available.
Process
1. Selection of the Critical Asset (Facilities)
2. Perform Failure Mode and Effect Criticality
Analysis (FMECA) to find effective task
(Seven Questions)
3. What are Challenges in the RCM
Implementation
4. Common Tools and Techniques employed.
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4. RCM Seven Basic Questions (Methodology)
Framework of RCM SAE JA1011 “Evaluation Criteria for RCM
Processes” 7 Rules For Successful Asset Optimization
Q 1: What are the functions and associated performance
standards of the asset in its present operating context?
Q 2: In what ways can it fail to fulfill the required functions?
Q 3: What causes each functional failure ?
Q 4: what happens when each failure occurs?
Q 5: In what way does each failure matter ?
Q 6: What can be done to predict or prevent each failure?
Q 7: What should be done, if a suitable proactive task cannot
be found ?
Function
Function failure
Failure mode
Failure Effect
Failure consequences
Maintenance Task
Other Maintenance Task
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5. Develop A Plan
An approach how to Perform the RCM
Analysis
1. Set up systems for measuring and Monitoring
progress.
2. Roles and responsibilities to ensure greater
accountability
Set Team Goals (KPI)
1. Maximize Equipment Effectiveness (OEE)
2. Zero Unscheduled Breakdowns
3. Zero Quality Defects
4. Zero Accidents
5. Minimum Cost (lifecycle of the assets)
6. Mean Time Between Failure (MTBF)
7. Mean Time To Repair (MTTR) npragasam@yahoo.com 5

6. 6
Selection
Assemble your asset hierarchy
How can you identify those systems
1. Identifying the critical systems of the
selected asset for analysis.
2. Selecting the critical subsystems using 80/20
Pareto analytical tool.
System 1 System 2 System 3
System 4
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7. Describing functions
For example, the primary
function of the pump :
1. To pump water from Tank X
to Tank Y at not less than
800 litres per minute.
No
Selected Component Q1 A
System Function
1 Pump To pump water from Tank X to
Tank Y.
Question 1A Functions
Example
Example
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8. Examples
Performance standards
When the functions are identified and
expressed in a verb–noun format, the
final step is establishing its
measurement.
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The performance defined in two ways, as follows:
1. Intial capability
• (what it can do) restore the asset to its initial level of capability.
2. Desired performance
• (what the user wants the asset to do) machine performance specifications.
Question 1B
No System Function Performance
Standard
1 Pump To pump water from Tank X to
Tank Y.
800 liters per minute
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9. 9
A functional Failure Analysis is defined as the inability of an asset to
fulfill one or more intended function(s) to a performance standard
Categorized
1. Total function failure
2. Partial function failure
Selected
Component
Q1 A Q1 B Q 2
Component Function Performance Standard Function Failure
Pump To pump water from Tank
X to Tank Y at not less
than 1000 liters per
minute.
800 litres per minute Unable to pump any water
Pump less than 800 liters
per minute.
Question 2 Function Failure
Examples
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10. A failure mode could be defined as any event
which is likely to cause an asset (or system or
process) to fail.
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While recording failure
modes.
• Failures which have
occurred before
• Not occurred but
considered to be
potential possibilities.
Question 3 Failure Mode
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11. 11
No Normal Correct way √
1 Valve jams Valve jams closed due to rust on
lead screw
2 Bearing seizes Bearing seizes due to lack of
lubrication
The difference in Describing a Failure Mode?
Question 3 Failure Mode
Examples
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12. 12
Q1 B Q 2 Q 3
Performance
Standard Functional Failure Failure Mode
800 litres per
minute
Unable to pump any water
1 Bearing seize due to no lubrication
2
Impeller jams due to foreign material
clogged
3
Shaft bent due to rust accumulation at
casing
Pump less than 1000 liters per
minute.
1 Impeller worn out due cavitation
2 Pump and motor misalignment of due to
set up
Examples
Question 3 Failure Mode
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13. Evident to the operators that a failure has occurred.
Warning lights to come on or alarms to sound (or both).
Motor trips out and trip alarm sounds in the control room.
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1. Tank Y low level alarm
sounds after 20 minutes, and
tank runs dry after 30
minutes.
2. Downtime required to replace
the bearings 4 hours
3. Maintenance cost RM 4,000
Question 4A Failure Effect
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14. Q 2 Q 3 Q 4A
Functional Failure Failure Mode Failure Effect
Unable to pump any
water
Bearing seize due to no
lubrication
Motor trips, alarm sounds in control room, 4
Hours downtime to replace the faulty bearings
Impeller jams due to foreign
material clogged
Motor trips, alarm sounds in control room, 2
hours downtime to remove the foreign material
and clean the impeller
Shaft dented to due rust
accumulation
Motor trips, alarm sounds in control room, 4
Hours downtime to repace the bent shafts
Pump less than 800
liters per minute.
Impeller worn out due cavitation
No alarm sounds in control room, 4 Hours
downtime to replace the impeller
Misalignment pump and motor
imbalance due to set up
No alarm sounds in control room, 2 Hours
downtime to realign the motor and pump
assembly
Question 4A Failure Effect
Examples
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15. Assign Severity (S) Rankings
The severity ranking is based on a
relative scale ranging from 1 to 10.
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• A “10” means the effect has a
dangerously high severity
leading to a hazard without warning.
• Similarly, a severity ranking of “1”
means the severity is extremely
low.
• Be consistent when assigning
occurrence
Assign Occurrence (O) Rankings
The occurrence ranking scale,
like the severity ranking, is on a
relative scale from 1 to 10.
Assign Detection (D) Rankings
The occurrence ranking scale, like
the severity ranking, is on a
relative scale from 1 to 10.
Severity (S) Occurrence(O) Detection(D) Rankings
and Risk Priority Numbers (RPN) Guidelines
Question 4B
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16. Examples
Q 3 Q 4A Q 4B
Failure Mode Failure Effect Severity Occurrence Detection RPN
Bearing seize due to no
lubrication
Motor trips, alarm sounds in control room, 3
Hours downtime to replace the faulty
bearings
5 4 1 20
Impeller jams due to
foreign material clogged
Motor trips, alarm sounds in control room, 2
hours downtime to remove the foreign
material and clean the impeller
4 5 1 20
Shaft dented to due rust
accumulation
Motor trips, alarm sounds in control room, 4
Hours downtime to replace the bent shafts
4 3 1 12
Impeller worn out due
cavitation internal wear
No alarm sounds in control room, 4 Hours
downtime to replace the impeller
4 2 4 32
Misalignment pump and
motor imbalance due to
set up
No alarm sounds in control room, 2 Hours
downtime to realign the motor and pump
assembly
4 2 4 32
Question 4B Severity (S) Occurrence(O) Detection(D) Rankings
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17. 17
In what ways it poses a
threat
1. Safety
2. Environment
3. In what ways it affects
operations and non
operation
4. What must be done to
address each the failure.
RCM Q5 Failure Consequence
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18. Q 4B Q 5
Severity Occurrence Detection RPN Safety Environment Operation Non Operation
5 4 1 20 NA NA Applicable NA
4 5 1 20 NA NA Applicable NA
4 3 1 12 NA NA Applicable NA
4 2 4 32 NA NA Applicable NA
4 2 4 32 NA NA Applicable NA
Question 5 Failure Consequence
Examples
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19. Question 6
What can be done to predict or prevent each failure?
Preventive Maintenance (PM)
• Schedule of planned maintenance
actions aimed at the prevention of
breakdowns and failures
• Primary goal-Preserve and enhance
equipment reliability
• Optimize the use of available resources
• Time-based preventive maintenance
• Usage-based preventive maintenance
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20. Predictive Maintenance
1. Vibration analysis
2. Lubricant/fluid analysis
3. Infrared thermography analysis
4. Electrical and motor current
analysis
5. Acoustic ultrasonic analysis
• Detect possible defects and fix them
before they result in failure.
• Uses condition-monitoring tools
• Failure modes that can be cost-effectively
predicted with regular monitoring
More Actionable InformationQuestion 6
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21. 1. Scheduled discard
2. Corrective maintenance,
3. Repair at failure,
4. Run-to-failure.
5. Redesign
Equipment
performance Substitution
Repair
Time until failure
Repair time
Time
Question 7 Other Maintenance Strategies
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22. Does the failure mode cause a
loss of function or could cause
injuries, disablement or death
Does the failure mode cause a loss of function
or damage which could breach known
environmental standards or regulation
no no
Is a task to detect whether the failure is occurring or
about to occur technically feasible and worth doing ?
Is a scheduled restoration task to avoid failures
technically feasible and worth doing
Is a scheduled discard task to avoid failures technically
feasible and worth doing
Is a combination of tasks to avoid failures technically
feasible and worth doing
yes
no
no
no
no
yes
yes
yes yes
yes
Safety Environment
Combination of tasks Redesign is mandatory
Predictive Maintenance
(Scheduled On-Condition
Task)
Planned Maintenance
(Scheduled Restoration
Task)
No Schedule
Maintenance (Run
to Failure)
Task Selection Decision TreeThe decision logic
tree passes each
failure mode one by
one,
“Yes or No tree,”
which pinpoints the
nature of the failure
mode consequence.
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23. Is a task to detect whether the failure is occurring or
about to occur technically feasible and worth doing ?
Is a scheduled restoration task to reduce failure rate
technically feasible and worth doing
Is a scheduled discard task to reduce the failure
rate technically feasible and worth doing
yes
no
no
no
yes
yes
yes
Schedule Predictive
Maintenance
(Scheduled On-Condition Task
Schedule Planned Maintenance
(Scheduled Restoration Task)
no
Redesign may be desirable
Operation
Does the failure mode have a direct adverse
effect on operational capability ( output,
quality, customer services, or operating costs
in addition to direct cost of repair ?
Does not pose a
direct effect on
operational
capability
no
Non-operation
yes
No Schedule
Maintenance (Run to
Failure)
1. Determine
what could
be done to
predict or
prevent
failure.
2. prevent the
asset from
failing.
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24. Q 4 Q 5 Q6/Q7
Severity Occurrence Detection RPN Safety Environment Operation
Non
Operation
Recommended Task
5 4 1 20 NA NA Applicable NA
Perform monthly inspection
and lubrication
4 5 1 20 NA NA Applicable NA
Perform monthly inspection
and cleaning
4 3 1 12 NA NA Applicable NA
Perform monthly inspection
and vibration analysis
4 2 4 32 NA NA Applicable NA Perform vibration analysis
4 2 4 32 NA NA Applicable NA
Perform vibration analysis
Q 6/7 Recommended /Other Task
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25. The Bottom Line:
1. Trained operators.
2. Trained maintenance.
3. Solid PM /PdM schedules.
4. How to deliver cost-effective over the lifecycle
of the assets.
End of Session
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