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Rcm
1.
© Imants http://www.managementsupport.com The
RCM Guide Reliability Centered Maintenance © Imants http://www.managementsupport.com
2.
© Imants http://www.managementsupport.com The
RCM Guide 1. Definitions
3.
© Imants http://www.managementsupport.com 1.
RCM definitions (1) • Reliability Centered Maintenance (RCM) is a methodology used to determine the right maintenance tasks to ensure that any physical asset or system continues whatever its users want it to do, in its present operating context
4.
© Imants http://www.managementsupport.com 1.
RCM definition (2) Reliability - The probability that equipment will not fail in a given time period - = a measure of the frequency of downtime
5.
© Imants http://www.managementsupport.com 1.
RCM definition (3) Maintenance - Any activity carried out on an asset in order to - ensure that the asset continues to perform its intended functions - repair the asset
6.
© Imants http://www.managementsupport.com The
RCM Guide 2. History
7.
© Imants http://www.managementsupport.com 2.
RCM History • 60’s: RCM developed in the airline industry • 70’s: RCM used in the army and the American Navy • 1978: first use of the term “Reliability Centered Maintenance” in Nowlan & Heap’s book: this book showed that a strong correlation between age and failure rate did not exist • 80’s - 90’s: transfer of the RCM methodology to other industrial sectors (railways, chemical industry)
8.
© Imants http://www.managementsupport.com The
RCM Guide 3. Objectives
9.
© Imants http://www.managementsupport.com 3.
RCM Objectives (1) • Determine the optimum maintenance program • Optimize your maintenance efforts • focus on the most important functions of the systems • avoid maintenance actions that are not strictly necessary • Strive for the required reliability • at the lowest cost • without sacrificing safety • without sacrificing the environment
10.
© Imants http://www.managementsupport.com 3.
RCM Objectives (2) • Establish maintenance practices which focus more on • the functional importance of a piece of equipment and its failure/repair history • and less on • vendor PM recommendations • traditional “time-directed” overhaul tasks
11.
© Imants http://www.managementsupport.com The
RCM Guide 4. Principles
12.
© Imants http://www.managementsupport.com 4.
RCM principles • 4.1. RCM is Business-Oriented • 4.2. RCM is Function Oriented • 4.3. RCM is System Focused • 4.4. RCM investigates how Equipment Fails • 4.5. RCM defines the best Maintenance Strategy based on the consequences of failures • 4.6. RCM acknowledges Design Limitations • 4.7. RCM is an Ongoing Task
13.
© Imants http://www.managementsupport.com 4.
RCM principles 4.1. Business oriented • Maintenance is business oriented (not only technical oriented): • operations efficiency • quality • cost • safety • environment
14.
© Imants http://www.managementsupport.com 4.
RCM principles 4.2. Function oriented • RCM focuses on preserving the functions of equipment, not on preserving the equipment itself • Equipment function: what its users want it to do • 2 function categories • primary functions: speed, output, product quality • secondary functions: safety, comfort, environmental integrity
15.
© Imants http://www.managementsupport.com 4.
RCM principles 4.3. System focused • RCM is more concerned with maintaining the system function, than individual component function • If the system still provides its primary function if a component fails, the component is allowed to run to failure
16.
© Imants http://www.managementsupport.com 4.
RCM principles 4.4. RCM investigates how equipment fails (1) • Failure: • a failure is the inability of an equipment, system or plant to fulfill one or more of its intended functions • Failure mode: • what is wrong • what we need to prevent or physically fix • Failure cause: • why it went wrong • Failure effect: • the consequence of the failure mode, when it occurs
17.
© Imants http://www.managementsupport.com 4.
RCM principles 4.4. RCM investigates how equipment fails (2) • Failure patterns: • the relationship between the probability of failure of an item, and its age (see Maintenance Management Guide) • RCM seeks to know the probability of failures at specific ages AGE Prob. Of Failure
18.
© Imants http://www.managementsupport.com 4.
RCM principles 4.5. RCM defines Maintenance Strategy • Based on the consequences of failures, the best maintenance strategy is defined • Run to Failure (RTF) • Preventive Maintenance (PM) · • Predictive Maintenance (PDM) • Proactive Maintenance (PAM) • Condition-based or predictive maintenance strategies are favored over traditional time- based methods
19.
© Imants http://www.managementsupport.com 4.
RCM principles 4.6. RCM recognizes Design Limitations • A maintenance program can only maintain the level of reliability inherent in the system design • No amount of maintenance can overcome poor design • Maintenance knowledge is fed back to designers to improve the next design
20.
© Imants http://www.managementsupport.com 4.
RCM principles 4.7. RCM is an ongoing task • The full benefit of RCM is only achieved when operation and maintenance experience is continuously fed back into the analysis process.
21.
© Imants http://www.managementsupport.com The
RCM Guide 5. Tools
22.
© Imants http://www.managementsupport.com 5.
RCM tools • 5.1. Selection and prioritizing tool • Pareto analysis • 5.2. Failure analysis tool • FMECA • 5.3. Reliability Modeling tools • Reliability Block Diagram • Fault Tree • 5.4. Decision Tool • Decision Tree analysis
23.
© Imants http://www.managementsupport.com 5.
RCM tools 5.1. Pareto analysis (1) • Pareto analysis is a selection and prioritizing tool • Pareto analysis (sometimes referred to as the 80/20 rule and as ABC analysis) is a method of classifying items, events, or activities according to their relative importance • Pareto analysis is based on the premise that 80 % of problems are due to 20 % of the possible causes
24.
© Imants http://www.managementsupport.com 5.
RCM tools 5.1. Pareto analysis (2) • Steps • sort data in descending order of importance • calculate individual percentages for each category • calculate cumulative percentages for each category • all categories with cumulative % less than or equal to 80 % can be selected for further review
25.
© Imants http://www.managementsupport.com 5.
RCM tools 5.1. Pareto chart Problem Causes % 20 40 60 80 100 A B C D E F ... O P 42 62 80 100
26.
© Imants http://www.managementsupport.com 5.
RCM tools 5.2. FMECA (1) • Failure Mode, Effect and Criticality Analysis is a Failure Analysis tool • It is a step-by-step procedure for the systematic evaluation of the failure effects and the criticality of potential failure modes in equipment and plant • A standard form (next slide) must be filled out
27.
© Imants http://www.managementsupport.com 5.
RCM tools 5.2. FMECA (2): standard form Item Function Failure mode Failure cause Failure effect Failure detection Failure isolation Actions Severity
28.
© Imants http://www.managementsupport.com 5.
RCM tools 5.3.1. Reliability Block Diagram (RBD) analysis (1) • RBD is a Reliability Modeling tool, and is constructed to assess the overall system reliability • A Reliability Block Diagram graphically represents the logical interaction of components within your systems • The components are arranged by blocks, and are related reliability-wise
29.
© Imants http://www.managementsupport.com 5.
RCM tools 5.3.1. Reliability Block Diagram (RBD) analysis (2) A D B 0.9 0.8 0.7 A,B,..: Components Numbers: availability
30.
© Imants http://www.managementsupport.com 5.
RCM tools 5.3.2. Fault Tree Analysis (FTA) (1) • FTA is a Reliability Modeling tool • FTA specifies a top event (ex. a fire) to analyze, followed by identifying all of the elements in the system that could cause the top event to occur • A symbolic logic diagram with AND/OR gates is constructed
31.
© Imants http://www.managementsupport.com 5.
RCM tools 5.3.2. Fault Tree Analysis (FTA) (2) Top event Failure 1 Failure 2 OR Failure 3 Failure 4 AND
32.
© Imants http://www.managementsupport.com 5.
RCM tools 5.4. Decision Tree analysis (1) • A Decision Tree Diagram is a graphical illustration in which lines branch out from a central point without forming any closed loops • The Decision Tree Diagram guides the user through a question-and-answer process • Options are ranked in an order of preference
33.
© Imants http://www.managementsupport.com 5.
RCM tools 5.4. Decision Tree analysis (2) ? ? ? YES YES NO NO YES NO Option 1 Option 2 Option 3 Option 4
34.
© Imants http://www.managementsupport.com The
RCM Guide 6. RCM analysis
35.
© Imants http://www.managementsupport.com 6.
RCM analysis • 6.1. Study preparation • 6.2. System selection and definition • 6.3. System function definition • 6.4. Functional failures definition • 6.5. Failure modes analysis • 6.6. Failure consequences assessment • 6.7. Selection of maintenance actions • 6.8. Data collection and documentation
36.
© Imants http://www.managementsupport.com 6.
RCM analysis 6.1. Study Preparation • Establishment of an RCM project group • one person from the maintenance function • one person form the operations function • an RCM specialist • Definition of objectives and scope of the analysis • Definition of boundary conditions with respect to safety and environmental protection
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RCM analysis 6.2. System Selection and Definition • The description of the assembly hierarchy (plant register) is a good standing point for system selection and definition • Tools: • Pareto analysis, • Reliability Block Diagram analysis, • Fault Tree Analysis To which systems are an RCM analysis beneficial compared with more traditional maintenance planning? At what level of assembly (plant, system, subsystem …) should the analysis be conducted?
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RCM analysis 6.3. System function definition • Identify and describe the system’s required functions and performance standards in its present operating context • Describe input interfaces required for the system to operate What are the functions and the associated desired standards of performance of the asset in its present operating context?
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RCM analysis 6.4. Functional failures definition • Identify the ways in which • the system might fail to fulfill its functions • the system functions at an unacceptable level of performance In what way can the asset fail to fulfill its functions?
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RCM analysis 6.5. Failure modes analysis • The objective of this step is to identify the events which cause the failure • normal wear • human errors • design • Tool: FMECA What causes each functional failure?
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RCM analysis 6.6. Failure consequences assessment • Failures which affect production / operations • Failures which threaten • safety • the environment • Failures which entail the direct cost of repair • Tool: FMECA What happens when the failure occurs?
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RCM analysis 6.7. Selection of Maintenance Actions (1) • Only applicable and cost-effective tasks may be selected • Applicability:a PM task will be applicable if it can eliminate a failure, or at least reduce the probability of occurrence to an acceptable level - or reduce the impact of failures! • Cost-effectiveness: the cost of performing the maintenance is balanced with the "cost" of not performing it. What should be done to predict or prevent each failure?
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RCM analysis 6.7. Selection of Maintenance Actions (2) • Tool: Decision Tree analysis • Options • do nothing: run to failure • prevent: scheduled or non-scheduled tasks • predict: checking the condition of equipment and detecting failure • redesign • equipment • process • procedures
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RCM analysis 6.8. Data Collection and Documentation • The data necessary for the RCM analysis may be categorized and collected in the following three groups: • Design data • Operational data • Reliability data • The revised tasks and procedures must be documented in a way that ensures that they will be easily understood and performed by the people who do the work
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RCM Guide 7. Implementation
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RCM implementation Eight implementation steps (1) 1. Define the scope and objectives of the project 2. Establish review groups • facilitator • project manager • operations personnel • functions and performance standards • maintenance personnel • types of failures • most appropriate condition monitoring techniques • maintenance and operations personnel • consequences of identified failures
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RCM implementation Eight implementation steps (2) 3. Train the review group 4. Estimate the amount of time to review the selected equipment 5. Plan meetings • date • time • location
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RCM implementation Eight implementation steps (3) 6. Plan senior management audits Senior management has to agree on • definition of functions and performance standards • identification of failure modes • description of failure effects • assessment of failure consequences • selection of tasks 7. Implement the selected tasks 8. Document the tasks and procedures
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RCM Guide 8. Benefits
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RCM benefits (1) • Cost saving • shift from time-based to condition-based work • workload reduction • spare part usage reduction • improved operation performance • Rationalization • unnecessary preventive work is eliminated • Improved safety • Improved environmental integrity
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RCM benefits (2) • A precise and comprehensive maintenance database • during the analysis, information is gathered in a coherent form • Education • improved overall level of skill and technical knowledge • Improved teamwork • Greater motivation of individuals
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RCM Guide 9. CMMS and RCM integration
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CMMS and RCM integration • Constant evolution to integrate RCM software in the Computerized Maintenance Management Systems: • Reliability Prediction Programs • Reliability Modeling Programs • FMEA / FMECA Programs • RCM databases • Links: • http://www.relexsoftware.com/ • http://www.sohar.com/software/meadep/ • http://www.itemsoft.com/
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