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Rcm terminology and concepts

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RCM term and concept, useful for reliability engineers

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Rcm terminology and concepts

  1. 1. Module 3Module 3 UNIT IUNIT I "Copyright 2002, Information Spectrum, Inc. All Rights Reserved." INTRODUCTION TO RCMINTRODUCTION TO RCMINTRODUCTION TO RCMINTRODUCTION TO RCM RCM TERMINOLOGY ANDRCM TERMINOLOGY AND CONCEPTSCONCEPTS RCM TERMINOLOGY ANDRCM TERMINOLOGY AND CONCEPTSCONCEPTS
  2. 2. IntroductionIntroductionIntroductionIntroductionModule Preview:Module Preview:Module Preview:Module Preview: FailuresFailures IntroductionIntroduction SeveritySeverity Probability of FailureProbability of Failure ReliabilityReliability Types of MaintenanceTypes of Maintenance Review and SummaryReview and Summary CriticalityCriticality RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  3. 3. Module Objective:Module Objective:Module Objective:Module Objective: This module will introduce basicThis module will introduce basic concepts and terminology used in theconcepts and terminology used in the RCM process.RCM process. IntroductionIntroductionIntroductionIntroduction RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  4. 4. Module Objective:Module Objective:Module Objective:Module Objective: IntroductionIntroductionIntroductionIntroduction 1. Define Failure Terminology:1. Define Failure Terminology: Functional FailureFunctional Failure Potential FailurePotential Failure Failure ModeFailure Mode 2. Introduce the concepts of2. Introduce the concepts of SeveritySeverity,, Probability of FailureProbability of Failure, and, and CriticalityCriticality and how they are related.and how they are related. RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  5. 5. Module Objective:Module Objective:Module Objective:Module Objective: IntroductionIntroductionIntroductionIntroduction 3. Introduce the concept of3. Introduce the concept of ReliabilityReliability.. 4. Define the following maintenance terms:4. Define the following maintenance terms: - Scheduled Maintenance - Unscheduled Maintenance- Scheduled Maintenance - Unscheduled Maintenance - Preventive Maintenance - Corrective Maintenance- Preventive Maintenance - Corrective Maintenance - Proactive Maintenance- Proactive Maintenance - Reactive Maintenance- Reactive Maintenance - Condition Monitoring- Condition Monitoring - Condition Based Maintenance- Condition Based Maintenance - Conditional Maintenance- Conditional Maintenance RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  6. 6. FAILURESFAILURESFAILURESFAILURES RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  7. 7. FailureFailureFailureFailureDefinitions:Definitions:Definitions:Definitions: 1.1. FAILUREFAILURE:: An identifiable deviation from aAn identifiable deviation from a specified condition that is unsatisfactory to anspecified condition that is unsatisfactory to an asset owner or manager.asset owner or manager. RCM recognizes two types of failures:RCM recognizes two types of failures: FUNCTIONAL FAILURE -FUNCTIONAL FAILURE - Inability of item toInability of item to perform a specific function within specifiedperform a specific function within specified performance limitsperformance limits POTENTIAL FAILURE –POTENTIAL FAILURE – DefinableDefinable andand detectable condition that indicates adetectable condition that indicates a functional failure will occurfunctional failure will occur RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  8. 8. FailureFailureFailureFailureDefinitions:Definitions:Definitions:Definitions: 2.2. FAILURE MODEFAILURE MODE -- A specific physicalA specific physical condition that causes a particularcondition that causes a particular functional failurefunctional failure RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  9. 9. SEVERITYSEVERITYSEVERITYSEVERITY RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  10. 10. SeveritySeveritySeveritySeverityDefinition:Definition:Definition:Definition: SEVERITYSEVERITY -- A category assigned to aA category assigned to a failure mode based on the impacts of itsfailure mode based on the impacts of its potential effectspotential effects …… qualitative measures used toqualitative measures used to categorize the potential effects of failures.categorize the potential effects of failures. RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  11. 11. CATEGORY I (CATASTROPHIC)CATEGORY I (CATASTROPHIC) • Death or Permanent disabilityDeath or Permanent disability • Destruction of system/equipmentDestruction of system/equipment • Significant breach of environmentalSignificant breach of environmental regulationregulation • Damage > $1MDamage > $1M CATEGORY III (MARGINAL)CATEGORY III (MARGINAL) • Damage >$10K and < $100KDamage >$10K and < $100K • Degraded ability to perform critical missionDegraded ability to perform critical mission • Interrupted operationsInterrupted operations CATEGORY II (CRITICAL)CATEGORY II (CRITICAL) • Personal InjuryPersonal Injury • Inability to perform primary missionInability to perform primary mission • Damage >$100K and < $1MDamage >$100K and < $1M CATEGORY IV (MINOR)CATEGORY IV (MINOR) • Unscheduled maintenance or repairUnscheduled maintenance or repair • Damage <$10KDamage <$10K Example:Example:Example:Example: SeveritySeveritySeveritySeverity Severity ClassificationsSeverity Classifications Aircraft ExampleAircraft Example Note: In some circumstances when an item performs a critical function and noNote: In some circumstances when an item performs a critical function and no effective back-up is available, loss of function for a defined period of time could beeffective back-up is available, loss of function for a defined period of time could be considered critical or catastrophic. These conditions should be added to the severityconsidered critical or catastrophic. These conditions should be added to the severity classifications as appropriateclassifications as appropriate RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  12. 12. CATEGORY I (CATASTROPHIC)CATEGORY I (CATASTROPHIC) • Death or Severe InjuryDeath or Severe Injury • Significant Environmental ImpactSignificant Environmental Impact • Loss of availability > 1 weekLoss of availability > 1 week • Damage > $1MDamage > $1M CATEGORY III (MARGINAL)CATEGORY III (MARGINAL) • Loss of availability > 4 hrs and < 24 hrsLoss of availability > 4 hrs and < 24 hrs • Damage >$10K and < $100KDamage >$10K and < $100K CATEGORY II (CRITICAL)CATEGORY II (CRITICAL) • Minor InjuryMinor Injury • Loss of availability > 24 hrs and < 7 daysLoss of availability > 24 hrs and < 7 days • Damage >$100K and < $1MDamage >$100K and < $1M CATEGORY IV (MINOR)CATEGORY IV (MINOR) • Loss of availability < 4 hrsLoss of availability < 4 hrs • Damage <$10KDamage <$10K Example:Example:Example:Example: SeveritySeveritySeveritySeverity Severity ClassificationsSeverity Classifications Plant Equipment ExamplePlant Equipment Example RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  13. 13. PROBABILITY OFPROBABILITY OF FAILUREFAILURE PROBABILITY OFPROBABILITY OF FAILUREFAILURE RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  14. 14. Probability of FailureProbability of FailureDefinition:Definition:Definition:Definition: 1.1. Probability of failureProbability of failure :: The probability that a given failureThe probability that a given failure mode will occur during a defined period.mode will occur during a defined period. 2.2. Acceptable Probability of Failure (PAcceptable Probability of Failure (Paccacc):): TheThe probability of a given failure mode occurring during a defined periodprobability of a given failure mode occurring during a defined period that is acceptable to a program or asset manager.that is acceptable to a program or asset manager. • The more severe the consequences, the lowerThe more severe the consequences, the lower PPaccacc should beshould be • Values may be defined by regulatory organizationsValues may be defined by regulatory organizations or self imposed (by a program or asset manager)or self imposed (by a program or asset manager) • Values should be documented prior to analysisValues should be documented prior to analysis RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  15. 15. Probability of FailureProbability of FailureProbability of FailureProbability of FailureDefinition:Definition:Definition:Definition: 3.3. Actual Probability of FailureActual Probability of Failure (P(Pactact)):: The predictedThe predicted or demonstrated probability of a given failure mode occurring duringor demonstrated probability of a given failure mode occurring during a defined period in the operating environment.a defined period in the operating environment. PPactact can be measured from in-service data or estimatedcan be measured from in-service data or estimated from statistical failure distributionsfrom statistical failure distributions RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  16. 16. CRITICALITYCRITICALITYCRITICALITYCRITICALITY RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  17. 17. CRITICALITY -CRITICALITY - A prioritization of theA prioritization of the combination of failure severity and failurecombination of failure severity and failure frequency (or probability)frequency (or probability) • Sometimes referred to asSometimes referred to as RiskRisk • Criticality may beCriticality may be documented qualitativelydocumented qualitatively or quantitativelyor quantitatively (Ref: MIL-STD-1629)(Ref: MIL-STD-1629) • Asset managers/Programs may defineAsset managers/Programs may define acceptable criticality limitsacceptable criticality limits by use of aby use of a Hazard Risk Matrix. (Qualitative Method)Hazard Risk Matrix. (Qualitative Method) • Criticality can be used to set priorities forCriticality can be used to set priorities for analysis or define acceptable riskanalysis or define acceptable risk CriticalityCriticalityCriticalityCriticalityDefinition:Definition:Definition:Definition: RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  18. 18. Hazard Risk Matrix:Hazard Risk Matrix:Hazard Risk Matrix:Hazard Risk Matrix: FREQUENCYFREQUENCY SEVERITYSEVERITY FREQUENTFREQUENT (A)(A) >> 1 per 1,0001 per 1,000 HoursHours PROBABLEPROBABLE (B)(B) >> 1 per 10,0001 per 10,000 HoursHours OCCASIONALOCCASIONAL (C)(C) >> 1 per 100,0001 per 100,000 HoursHours REMOTEREMOTE (D)(D) >> 1 per 1,000,0001 per 1,000,000 HoursHours IMPROBABLEIMPROBABLE (E)(E) << 1 per 1,000,0001 per 1,000,000 HoursHours CATASTROPHIC (I)CATASTROPHIC (I) CRITICAL (II)CRITICAL (II) MARGINAL (III)MARGINAL (III) MINOR (IV)MINOR (IV) • Death or Permanent disabilityDeath or Permanent disability • Significant Environmental breachSignificant Environmental breach • Damage > $1M, Downtime>2 daysDamage > $1M, Downtime>2 days • Destruction of system/equipmentDestruction of system/equipment • Personal InjuryPersonal Injury • Damage >$100K and < $1MDamage >$100K and < $1M • Loss of availability > 24 hrs andLoss of availability > 24 hrs and < 7 days< 7 days • Damage >$10K and < $100KDamage >$10K and < $100K • Loss of availability > 4 hrs andLoss of availability > 4 hrs and < 24 hrs< 24 hrs • Damage <$10KDamage <$10K • Loss of availability < 4 hrsLoss of availability < 4 hrs 11 HIGHHIGH 33 HIGHHIGH 44 HIGHHIGH 22 HIGHHIGH 55 HIGHHIGH 88 MEDMED 66 MEDMED 77 MEDMED 99 MEDMED 1010 LOWLOW 1212 ACCEPTACCEPT 1313 ACCEPTACCEPT 1515 ACCEPTACCEPT 1616 ACCEPTACCEPT 1717 ACCEPTACCEPT 2020 ACCEPT 1919 ACCEPT 1414 ACCEPT 1111 LOWLOW 1818 ACCEPTACCEPT CriticalityCriticalityCriticalityCriticality RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  19. 19. RELIABILITYRELIABILITYRELIABILITYRELIABILITY RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  20. 20. ReliabilityReliabilityReliabilityReliability RELIABILITY -RELIABILITY - Probability that anProbability that an asset will perform its intendedasset will perform its intended function for a specified period of timefunction for a specified period of time under specified operating conditionsunder specified operating conditions Actual Reliability is a function of the asset’s design,Actual Reliability is a function of the asset’s design, manufacturing process, usage profile, operatingmanufacturing process, usage profile, operating environment, and maintenance program.environment, and maintenance program. Definitions:Definitions:Definitions:Definitions: RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  21. 21. MAINTENANCEMAINTENANCE TERMSTERMS MAINTENANCEMAINTENANCE TERMSTERMS RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  22. 22. Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition: PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE – actions– actions performed periodically (or continuously)performed periodically (or continuously) prior to functional failure (or multipleprior to functional failure (or multiple failure/demand requirements for hiddenfailure/demand requirements for hidden failures) to achieve the desired level offailures) to achieve the desired level of safety and reliability for an itemsafety and reliability for an item …… These actions are performed to prevent orThese actions are performed to prevent or reduce consequences of failures.reduce consequences of failures. Due to differences in the way the termDue to differences in the way the term ScheduledScheduled MaintenanceMaintenance is used, this course will attempt to use theis used, this course will attempt to use the termterm Preventive MaintenancePreventive Maintenance onlyonly RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  23. 23. Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinitionDefinitionDefinitionDefinition • PROACTIVE MAINTENANCEPROACTIVE MAINTENANCE – any tasks– any tasks used to predict or prevent equipmentused to predict or prevent equipment failures.failures. Similar toSimilar to Preventive MaintenancePreventive Maintenance except that itexcept that it generally excludes failure finding type tasks. Again,generally excludes failure finding type tasks. Again, definitions may vary…definitions may vary… RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  24. 24. Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition: • CORRECTIVE MAINTENANCECORRECTIVE MAINTENANCE –– repairsrepairs or other corrective action taken after aor other corrective action taken after a failure has occurredfailure has occurred For the purposes of this course, the termFor the purposes of this course, the term UnscheduledUnscheduled MaintenanceMaintenance is synonymous withis synonymous with Corrective MaintenanceCorrective Maintenance andand Reactive MaintenanceReactive Maintenance RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  25. 25. Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition: • CONDITION MONITORING –CONDITION MONITORING – The use ofThe use of specialized equipment to measure thespecialized equipment to measure the condition of equipment.condition of equipment. Vibration Analysis, Oil Analysis, and ThermographyVibration Analysis, Oil Analysis, and Thermography are examples ofare examples of Condition MonitoringCondition Monitoring techniquestechniques Predictive Maintenance (PdM) and Prognosis and HealthPredictive Maintenance (PdM) and Prognosis and Health Management (PHM) are usually interchangeable withManagement (PHM) are usually interchangeable with Condition Monitoring.Condition Monitoring. RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  26. 26. Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition: • Condition Based MaintenanceCondition Based Maintenance – An– An equipment maintenance strategy basedequipment maintenance strategy based on measuring the condition ofon measuring the condition of equipment in order to assess whetherequipment in order to assess whether it will fail during some future period,it will fail during some future period, and then taking appropriate action toand then taking appropriate action to avoid the consequences of that failure.avoid the consequences of that failure. RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  27. 27. Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition: • Conditional or Opportunity MaintenanceConditional or Opportunity Maintenance –– Maintenance actions conducted as result of aMaintenance actions conducted as result of a specific condition, or as a result of specificspecific condition, or as a result of specific circumstances or events.circumstances or events. Examples of Conditional InspectionsExamples of Conditional Inspections • Hard LandingHard Landing • Unscheduled disassemblyUnscheduled disassembly • Power InterruptionPower Interruption • Over/Under VoltageOver/Under Voltage • Lightning strikeLightning strike • Over stressOver stress • Unscheduled or scheduled shut-downUnscheduled or scheduled shut-down RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  28. 28. Proactive MaintenanceProactive Maintenance Preventive Maintenance (PM)Preventive Maintenance (PM) Unscheduled MaintenanceUnscheduled Maintenance Corrective Maintenance (CM)Corrective Maintenance (CM) Reactive MaintenanceReactive Maintenance Condition Based MaintenanceCondition Based Maintenance Condition MonitoringCondition Monitoring Predictive MaintenancePredictive Maintenance Prognosis Health Management (PHM)Prognosis Health Management (PHM) Potential failuresPotential failures Repairs or corrective actionsRepairs or corrective actions Run to failureRun to failure Failure has occurredFailure has occurred Preserves required functionality Reduces unplanned downtime Requires investment Fixes failures in unplanned manner Downtime unpredictable Addresses only “what’s broken” RCM determines proper balance of planned and unplanned maintenance,RCM determines proper balance of planned and unplanned maintenance, along with “Other Actions”, to establish a “Failure Management Strategy”along with “Other Actions”, to establish a “Failure Management Strategy” Scheduled MaintenanceScheduled Maintenance Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceSummary:Summary:Summary:Summary: RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  29. 29. Review and SummaryReview and SummaryReview and SummaryReview and Summary IntroductionIntroductionIntroductionIntroduction RCM Terms & ConceptsRCM Terms & ConceptsRCM Terms & ConceptsRCM Terms & Concepts – Learning ObjectivesLearning Objectives – FailuresFailures – SeveritySeverity – Probability of FailureProbability of Failure – CriticalityCriticality – ReliabilityReliability – Maintenance TermsMaintenance Terms Module ObjectiveModule ObjectiveModule ObjectiveModule Objective – Introduce the primary terminologyIntroduce the primary terminology and basic concepts used in RCMand basic concepts used in RCM RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
  30. 30. End of Module up next…….. Unit II Module 1 RCM Process Overview End of Module up next…….. Unit II Module 1 RCM Process Overview

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