BAHAN PRESENTASI RCM

1. Streamline Reliability Centered
Maintenance (SRCM)

2. Untuk mamastikan alat produksi bekerja sepanjang waktu dengan
kemampuan yg optimal, maka diperlukan manajemen perawatan
(Reliability Maintenance) yang tepat sesuai dengan standar
internasional.
Kami memberikan solusi manajemen perawatan yang tepat
dengan berfokus kepada Reliability, yg akan menghasilkan biaya
operasional yg effisien, hasil produksi yg optimal serta keuntungan
produksi yang lebih besar.
Streamline RCM

3. Streamline RCM
RELIABILTY CENTERED MAINTENANCE (RCM) OBJECTIVES :
• To maintain or improve reliability and availability of plant
equipments/components
• To control costs optimize maintenance
• To analyzes all possible failures of a system and develops
mechanisms that try to avoid them, whether produced by intrinsic
causes of the equipment itself or by personal acts
• To determines a series of actions which ensure high plant
availability
• Optimize maintenance resources
• Optimize maintenance task
• Enhance Safety
• Improve PM/CM ratio
• Provide equipment life extension

4. Streamline RCM
REFERENCES :
• SAE JA 1012 Guide to the RCM Standard
• SAE JA 1011 Evaluation Criteria for RCM Process
• Streamline RCM Guideline
• SCE List (if applicable)
• Default Task (if applicable)
• ISO 14224 Reliability and Maintenance Data for Equipment

5. System
Screening
Job
Bundling
Check List
Hierarchy
Criticality
Asset
Register
Deliverable 1
Maintenance
Task
Development
Load
Leveling
Deliverable 2
Deliverable 3
Deliverable 4 Deliverable 5
Task
Development
•Maintenance Task
•Frequency (FTA, Eng.
Judgment)
•Lead Craft
•System Condition
RCM
Documents
•P&ID,SLD
•PFD
•Operation
Philosophy
Job Bundling
•Maintenance Task
•Frequency
•Lead Craft
•Package
•Campaign
•Regulatory Requirement
•Lead Craft
•Frequency
•Duration
•Start Date
•Graph per work center
Load Leveling
• Maintenance Task
• Frequency
• Lead Craft
• Task Duration
Check List
•High
•Significant
•Medium
•Low
Criticality and
FMEA
SCE
Documents
with Default
Criticality
Streamline RCM
Failure Mode
and Effect
Analysis

6. SRCM MAIN WORKFLOW

7. EQUIPMENT GROUPING &
HIERARCHY

8. EQUIPMENT GROUPING &
HIERARCHY

9. EQUIPMENT CRITICALITY
ANALYSIS
Purpose of Criticality Assessment :
• To identify the relative criticalities of equipment systems,
packages or equipment items
• To provide an input to reliability and safety.
Such an assessment process also give benefits :
• Concentration of efforts and resources on systems and
equipment that are most critical
• Application of more stringent engineering standards and
inspection on more critical equipment
• Development of detailed equipment-specific reliability and
spares strategies for highly critical items

10. EQUIPMENT CRITICALITY
ANALYSIS
Assessment Parameter:
• PROBABILITY OF FAILURE (PoF)
• HEALTH AND SAFETY
• ENVIRONMENT
• BUSSINES / ECONOMIC / PRODUCTION

11. CONSEQUENCE
OF
FAILURE
(CoF)
ECONOMICS (USD) < 10K 10 - 100K 0.1 - 1M 1 - 10M > 10M
HEALTH & SAFETY NO/SLIGHT INJURY MINOR INJURY MAJOR INJURY SINGLE FATALITY
MULTIPLE
FATALITIES
ENVIRONMENT NO/SLIGHT EFFECT MINOR EFFECT LOCAL EFFECT MAJOR EFFECT MASSIVE EFFECT
1 2 3 4 5
NEGLIGIBLE LOW MEDIUM HIGH EXTREME
PROBABILITY
OF
FAILURE
(PoF)
HIGH 0 - 0.5 YEAR HIGH 4 04 : LOW 08 : MEDIUM HIGH 12 : HIGH 16 : EXTREME 20 : EXTREME
MEDIUM 0.5 - 4 YEARS MEDIUM 3 03 : LOW 06 : MEDIUM 09 : MEDIUM HIGH 12 : HIGH 15 : EXTREME
LOW 4 - 20 YEARS LOW 2 02 : NEGLIGIBLE 04 : LOW 06 : MEDIUM 08 : MEDIUM HIGH 10 : HIGH
NEGLIGIBLE > 20 YEARS NEGLIGIBLE 1 01 : NEGLIGIBLE 02 : NEGLIGIBLE 03 : LOW 04 : MEDIUM
05 : MEDIUM
HIGH
RISK MATRIX

12. Data
Gathering
ID System/
Equipment
Assess Failure
Consequence
s
Assess Failure
Likelihood
Assess
Criticality
Identify
Delayed Cons
S,E,B,A
Likelihood
Modify Crt
Rating for
Redundancy
S,E,B,A
Assign
Criticality
Level
Develop Risk
Matrix
Develop FM
Database
EQ CRITICALITY
METHODOLOGY

13. EQUIP. CRITICALITY
(N, L, M, MH, H & E)
HIDDEN /
EVIDENT
FAILURE FINDING
Task Interval:
1. Operational Maintenance
2. Condition Maintenance
EXISTING
TASK / RTF
N & L
M, MH, H & E
HIDDEN
PREDICTIVE MAINTENANCE
Task Interval:
1. (0.3 – 0.5) PF Interval
2. Expert Judgment
3. Vendor Recommendation
EVIDENT
PREDICTIVE
MAINTENANCE
YES
NO
PREVENTIVE
MAINTENANCE
SCHEDULED DISCARD
Task Interval:
1. (MTBF/3) H & E
2. (MTBF/2) M & MH
3. Expert Judgment
SCHEDULED RESTORATION
Task Interval:
1. (0.3 – 0.5) MTBF
2. Expert Judgment
NO
YES
SRCM PM TASK SELECTION

14. Job Bundling, pengelompokan maintenance task yang
bertujuan memudahkan pelaksanaan kegiatan
maintenance, berdasarkan:
• General task.
• Regulation based maintenance task.
• Insolation or shutdown needed system.
Load Leveling, adalah system penyebaran beban man
hour secara merata sepanjang tahun dan dapat terpenuhi
dengan existing man hour
SRCM JOB BUNDLING & LOAD
LEVELING

15. Additional Keyword:
• Asset Register & Hierarchy
• Equipment Criticality Analysis
• FMEA
• Maintenance Task
• Job Bundling
• Job Leveling
• Fault Tree Analysis
• Reliability Accounting
• Reliability Monitoring, IT
• Maintenance Improvement
OUR CAPABILITIES ON RCM

16. THANK YOU