This is the presentation based on final year project which deals with the implementation of "Reliability Centered Maintenance and Contribution of Quality Management System". A case study analysis has also been attached in this presentation.

1. In the name of ALLAH, The entirely merciful, the
especially merciful;
Department of Mechanical Engineering 1

2. Implementation of Reliability Centered Maintenance
and Contribution of Quality Managment System:
A Case Study of Saif Power Ltd.
COMSATS Institute of Information Technology, Sahiwal
Department of Mechanical Engineering
Waseem Akram SP14-BME-045
Shahid Majeed SP14-BME-043
Nouman ul Hassan SP14-BME-013
Sufyan Ali SP14-BME-083
Presented by:
Supervised by:
Engr. Dr. Zahiruddin Shaikh
Department of Mechanical Engineering

3. Department of Mechanical Engineering
Outline
 Problem statement
 Aim of the work
 Litrature review
 Methodology
 Analysis and Results
 Benefits and difficulties
 Refrences
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4. Department of Mechanical Engineering
Problem statement
2
Breakdowns*
Equipment
Failure
Improper
maintenance
techniques
Poor
utilization of
resources
*is the failure of any equipment or machine in providing its correct operating condition.

5. Department of Mechanical Engineering
Aim of the work
Main Objectives:
 Implementation Of Reliability Centered Maintenance (RCM) in Saif Power Ltd.
 Contribution of Quality Managment System ISO 9001 in implementing RCM in any Industry
Sub Objectives:
 Effectiveness of the blend of Quality Managment System and Reliability Centered
Maintenance
 Optimum utilization of resources through implementaion of RCM
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6. Department of Mechanical Engineering
Literature Review
4
In Engineering,
 “Maintenance Engineering is the discipline and profession of applying
engineering concepts for the optimization of equipment, procedures, and
departmental budgets to achieve better maintainability, reliability, and
availability of equipment.”(Wikipedia)
 Reliability Centered Maintenance (RCM) is the process of determining the
most effective maintenance approach. The goal of the philosophy is to
provide the stated function of the facility, with the required reliability and
availability at the lowest cost. (Nowlan & Heap, 1978)
 Any organization can be benefited from RCM if its breakdowns account for
more than 20–25% of the total maintenance work load. (Igbaa, Friis ,2013)
 Reliability Centered Maintenance (RCM) is a way of capturing the potential
causes of downtime and poor performance by preventing failures and having
a proactive approach to Operations and Maintenance (O&M). (Khiat, 2014)

7. Department of Mechanical Engineering
Literature Review
 Reliability based maintenance is basically : (Vishnu, 2016)
• Proactive approach that prevents the failures likely to occur
• Implement to eliminate the source of failures
• Most effective maintenance approach to get reliability in the system
• Minimizes the failure occurrences which basically reduce breakdowns.
 Following figure is showing the processes used in RCM.
These processes are used in integrated manner to implement RCM. (MIL-HDBK-
2173, 1998)
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8. Department of Mechanical Engineering
Methodology
Conducting a Pilot Program
Building up a Business Case
Establishing a Long-term Vision
Benchmarking the Present Position
Educate from Top to Bottom on RCM
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Implementation methodology of RCM

9. Department of Mechanical Engineering
Methodology
Performance Evaluation
Implementation of RCM Process
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System
Selection
and
Definition Functional
Failure
Analysis &
Critical Item
Selection
Selection of
Maintenance
Action After FMEA
& FMECA
Implementation
Implementation Process

10. Department of Mechanical Engineering
Methodology
8
 Optimum set of guidelines will provide:
• Function Oriented
• System Focused
• Reliability Centered
• Acknowledge Design Limitation
• Driven by Safety and Economy
• Failure as any Unsatisfactory Condition
• Use a Logic Tree to screen Maintenance Task
• Acknowledge types of Maintenance basically three
• RCM is a Living System

11. Department of Mechanical Engineering
Analysis and Results
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 Contribution of Quality management system in implementing Reliability
Based Maintenance in an industry:
Here, our task is the contribution of QMS in implementing RCM in the industry
which is our case study. As we see the steps for achieving QMS and RCM in
previous slides, Now we will correlate them to optimize our task to implement
RCM.
 CORRELATION:
In correlating QMS and RCM, we will see the common points used in both RCM
and QMS, that will minimize the time schedule to complete our task.
Because the industry which is in our consideration is ISO certified, it means we
can get help from those set of activities which are in common between RCM
and QMS in that industry.

12. Department of Mechanical Engineering
Analysis and Results
10
• RCM: Step 1 “Education from top to bottom”
• QMS: provide medium for awareness and
communication
Awareness,
Communication
•RCM: needs that there must be documentation of every
activity being performed
•QMS: ensured that every activity in the organization is
already being documented
Documentation
• RCM: needs to know that where we are in the
present position to plan what we have to do in
future?
• QMS: “Context of the organization”
Benchmarking or realizing
the present situation
• RCM: demands that everyone should have to know
its roles and responsibilities.
• QMS: Already defined Roles and responsibilities for
each personnel
Roles and
Responsibilities
Correlation between RCM and QMS

13. Department of Mechanical Engineering
Analysis and Results
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• RCM: demands that safety should be the First
priority.
• QMS: ensured that there should not be any risky
behavior
Safety
• RCM: There should be a proper way to Audit the
activities and management should review
• QMS: already ensured the proper channel for this
Internal Audit,
Management Review
• RCM: needs that performance should be evaluated
after specific intervals
• QMS: “Performance evaluation” is basic
requirement of ISO 9001
Performance evaluation
• RCM: Leads towards a way of continuous
improvement
• QMS: also have the same goal at the end
Continual Improvement
Correlation between RCM and QMS

14. Department of Mechanical Engineering
Analysis and Results
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Case Study: SAIF POWER Ltd.
 Combined Cycle Power Plant
 Production Capacity: 225 MW
Selected Section: HRSG [Heat Recovery Steam Generator]
 Critical Components of HRSG
• Boiler
• Feed water Pump

15. Department of Mechanical Engineering
Analysis and Results
• Current maintenance Actions
• Proposed maintenance Actions
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Equipment Maintenance type Percentage
Boiler
Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
15%
65%
20%
Feed water pump
Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
20%
70%
10%
Equipment Maintenance type Percentage
Boiler
Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
5%
70%
25%
Feed water pump
Corrective Maintenance
Preventive Maintenance
Predictive Maintenance
10%
40%
50%

16. Department of Mechanical Engineering
Analysis and Results
Parameters Values
Checklists
Achieved availability
Material availability
Mean downtime
Maintenance cost
Maintenance man hours
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89.58%
92.35%
38.3 days
22.7 million
525. hours
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Parameters Values
Checklists
Achieved availability
Material availability
Mean downtime
Maintenance cost
Maintenance man hours
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92.8%
93.9%
26 days
18.6 millions
390 hours
• Pre-RCM
• Post-RCM

17. Department of Mechanical Engineering
Results
Analysis of those results provide:
• Checklists increased
• Over-maintenance reduced as Predictive maintenance increases
• Achieved availability increased by 3.22%
• Material availability increased by 1.55%
• Major reduction in downtime that is 38.3 days to 26 days, almost 33%
• Cost reduction of almost 18%
• Maintenance man hours decreased
• Enhanced safety as breakdowns/failure decreased.
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18. Department of Mechanical Engineering
Benefits and Difficulties
Benefits Difficulties
Combined effect of RCM and QMS will have:
• Enhanced reliability
• Cost-Effective plan
• Reduction in downtime
• Contribution to long term benefits
• Increase in material/parts availability
• A culture of economy performance
• Operation and maintenance interaction
• Feedback quality improved
• Maintenance workforce reduces
• A lot of time saved
There are some difficulties too:
• Can have significant startup costs
associated with staff training and
equipment needs
• Need some time to manage and
understand
• Required skilled personnel
• Complexity
• Extensive need for data
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19. Department of Mechanical Engineering
References
[1] https://en.wikipedia.org/wiki/Maintenance_engineering
[2] F.S. Nowlan, H.F. Heap, Reliability Centered Maintenance, published by
United Airlines, Washington D.C., (1978)
[3] Joel Igbaa, Kazem Alemzadeha, I. Anyanwu-Ebob, Paul Gibbonsa, John Friis,
A Systems Approach towards Reliability Centered Maintenance (RCM) of
Wind Turbines Procedia Computer Science (2013) 16: 814 – 823
[4] B. Yssaad, M. Khiat, A. Chaker, Reliability centered maintenance
optimization for power distribution systems, 2015, published by ELSEVIER,
Electric power and energy systems (2014) 55: 108-115
[5] Vishnu C. R., Regikumar V., Reliability Based Maintenance Strategy
Selection in Process Plants: A Case Study, Procedia Technology (2016) 25:
1080 – 1087
[6] MIL-HDBK-2173, Department of Defense, Handbook: Reliability-Centered
Maintenance (RCM) Requirements for Naval Aircraft, Weapons Systems
and Support Equipment, United States Department of Defense, (1998)
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20. Department of Mechanical Engineering
Any Query?