RCM

1. RCM --> structured approach that determines the most cost-effective
maintenance task for every (possible) failure of the installation
Studying the supplied Mainovation study and determining the way
forward as well as which template might be chosen (Hazop, RCA,
FMEA,...)

2. RCM --> structured approach that determines the
most cost-effective maintenance task for every
(possible) failure of the installation
 Possible failures of the installations
 Cost Effective Maintenance Tasks:

4. RCM --> structured approach that determines the
most cost-effective maintenance task for every
(possible) failure of the installation
 In general, failures affect operations in four ways:
 they affect total output. This occurs when equipment stops working altogether or when it works
too slowly. This results either in increased production costs if the plant has to work extra time to
catch up, or lost sales if the plant is already fully loaded.
 they affect product quality. If a machine can no longer hold manufac- turing tolerances or if a
failure causes materials to deteriorate, the likely result is either scrap or expensive rework. In a
more general sense, "quality" also covers concepts such as the precision of navigation sys- tems,
the accuracy of targeting systems and so on.
 they affect customer service. Failures affect customer service in many ways, ranging from the
late delivery of orders to the late departure of passenger aircraft. Frequent or serious delays
sometimes attract heavy penalties, but in most cases they do not result in an immediate loss of
revenue. However chronic service problems eventually cause customers to lose confidence and
take their business elsewhere.
 increased operating costs in addition to the direct cost of repair. For instance, the failure might
lead to the increased use of energy or it might involve switching to a more expensive alternative
process.

5.  Proactive Maintenance:
 The nature and severity of these effects govern the way in which the failure is viewed by the
organisation. The precise impact in each case - in other words, the extent to which each failure
matters - depends on the operating context of the asset, the performance standards which apply to
each function, and the physical effects of each failure mode.
 Proactive maintenance has much more to do with avoiding or reducing the
consequences of failure than it has to do with preventing the failures themselves
 A proactive task is worth doing if it deals successfully with the consequences of the
failure which it is meant to prevent
This of course presupposes that it is possible to anticipate or prevent the failure in the first place.
Whether or not a proactive task is technically feasible depends on the technical characteristics of the
task and of the failure which it is meant to prevent.

6. Hidden and Evident Failures
Failures of this kind are classed as evident because someone will eventually find out about it when they occur
on their own. This leads to the following definition of an evident function:
 An evident function is one whose failure will on its own eventually and inevitably become evident
to the operating crew under normal circumstances.
 A hidden function is one whose failure will not become evident to the operating crew under
normal circumstances if it occurs on its own.

7. Categories of Evident Failures
Evident failures are classified into three categories in descending order of importance, as
follows:
Safety and environmental consequences: A failure has safety consequences if it could hurt
or kill someone. It has environmental consequences if it could lead to a breach of any
corporate, regional or national environmental standard
Operational consequences: A failure has operational consequences if it affects production
or operations (output, product quality, customer service or operating costs in addition to the
direct cost of repair)
Non-operational consequences: Evident failures in this category affect neither safety nor
production, so they involve only the direct cost of repair.
By ranking evident failures in this order, RCM ensures that the safety and environmental
implications of every evident failure mode are considered. This unequivocally puts people
ahead of production.

8. Safety and Proactive Maintenance
 For failure modes which have safety or environmental consequences, a
proactive task is only worth doing if it reduces the probability of the failure to
a tolerably low level

9. Operational consequences
 In general, failures affect operations in four ways:
 they affect total output. This occurs when equipment stops working altogether or when it works too slowly. This results
either in increased production costs if the plant has to work extra time to catch up, or lost sales if the plant is already
fully loaded.
 they affect product quality. If a machine can no longer hold manufac- turing tolerances or if a failure causes materials
to deteriorate, the likely result is either scrap or expensive rework. In a more general sense, "quality" also covers
concepts such as the precision of navigation sys- tems, the accuracy of targeting systems and so on.
 they affect customer service. Failures affect customer service in many ways, ranging from the late delivery of orders
to the late departure of passenger aircraft. Frequent or serious delays sometimes attract heavy penalties, but in most
cases they do not result in an immediate loss of revenue. However chronic service problems eventually cause customers
to lose confidence and take their business elsewhere.
 increased operating costs in addition to the direct cost of repair. For instance, the failure might lead to the increased
use of energy or it might involve switching to a more expensive alternative process. In non-profit enterprises such as
military undertakings, certain failures can also affect the ability of the organisation to fulfil its primary function
sometimes with devastating results.
 Certain functions can effect the primanry functions of the organization that can have devastation results
 "For want of a nail, a shoe was lost. For want of a shoe, a horse was lost. For want of a horse, a message was
lost. For want of a message, a battle was lost. For want of a battle, a war was lost. All for want of a horseshoe
nail."

10.  The severity of these consequences mean that if an evident failure does not
pose a threat to safety or the environment, the RCM process focuses next on
the operational consequences of failure.
 A failure has operational consequences if it has a direct adverse effect on
operational capability

11. Avoiding Operational Consequences
Avoiding Operational Consequences The overall economic effect of any failure mode
which has operational consequences depends on two factors:
⚫ how much the failure costs each time it occurs, in terms of its effect on operational
capability plus repair costs
⚫ how often it happens. In the previous section of this chapter, we did not pay much
attention to how often failures are likely to occur.
(Failure rates have little bearing on safety-related failures, because the objective in
these cases is to avoid any failures on which to base a rate.) However, if the failure
consequences are economic, the total cost is affected by how often the consequences
are likely to occur. In other words, to assess the economic impact of these failures, we
need to assess how much they are likely to cost over a period of time.

12. RCM --> structured approach that determines the most cost-effective
maintenance task for every (possible) failure of the installation
 RCM:
 The response priority matrix is as follows:
 Priority Description Response time
 1. Emergency Same day
 2. Urgent 5 days
 3. High Priority 15 days
 4. Routine 30 days
 5. Deferred 90 days

13. RCM --> structured approach that determines the
most cost-effective maintenance task for every
(possible) failure of the installation
 In essence, it is the process used to determine the most effective approach to
maintenance by identifying actions that, when properly instituted will reduce
the probability of failure and which are most cost effective. (NASA RCM
Guide, 2000)

14. RCM --> structured approach that determines the
most cost-effective maintenance task for every
(possible) failure of the installation
 Reliability-centered maintenance analysis provides a basic framework for
analyzing the functions and potential failure modes for a physical asset in
order to develop a scheduled maintenance plan that will provide some
acceptable level of operability. (The term “acceptable level” needs to be
defined by each individual organization based on their individual needs of
whatever system it is that they wish to measure.) In addition, reliability-
centered maintenance should also take into account risk in some efficient,
cost-effective manner.

15. RCM --> structured approach that determines the
most cost-effective maintenance task for every
(possible) failure of the installation
 A well crafted reliability-centered maintenance program should (or could
depending on the size of the organization) incorporate
 condition based actions,
 time based actions,
 and run to failure. (NASA RCM Guide, 2000).

18. RCM --> structured approach that determines the most cost-
effective maintenance task for every (possible) failure of the
installation
 3.2.1 Cost The consideration of economic aspects of a component is the major
factor in its criticality. The total cost of a component with respect to maintenance
in the manufacturing industry includes
 (a) maintenance cost
 (b) component investment cost and
 (c) cost of production loss.
 In comparison to other components, if a component has a higher maintenance cost
then it needs to be assigned a higher criticality value. Maintenance cost directly
affects the availability of resources of repair and complexity of the
 component. Cost of production also directly depends on total downtime of the
system, which is controlled by the availability of resources to repair. Next, to
maintenance cost, cost of production loss and component investment cost are
assigned criticality values respectively

19.  3.2.2 Functional dependencies According to these criteria, the functional
dependence of a component in terms of process and their design is one of the main
factors in finding a critical component of a system. The design of a component has
its significant contribution in the system reliability indices. If a component is having
the leading role in the system but if the design of the component is not reliable,
then that particular component was assigned to be more critical from a design point
of view.
 3.2.3 Complexity To ensure the smooth operation of a manufacturing system, the
complexity of the component is of a great concern. This criterion is divided into
three sub-criterion as the probability of failure, total no. of parts and their failure
effect on the system. Component multiplicity will play an important role in finding
out the critical component. Amodule, which is having a large number of parts, will
have a significant contribution in the overall system reliability. In addition, at the
same time, the failure frequency and their effect on the system will affect the
system availability. A component with large no. of parts and high failure probability
is much more critical to maintain.

20.  3.2.4 Maintainability The fourth criterion is maintainability. Maintainability is
also having a significant role in identifying the critical component of a
manufacturing system. This criterion further classified into four sub-criteria
as the availability of technical specification, failure detection, total
downtime and facility required to repair. The repair process of some
components can sometimes take a long time resulting in large downtimes of
the system. In some cases, specific failures are difficult to detect because of
less availability of technical specification. In such cases, when a failure
occurs, the time to repair will considerably increase and will be difficult to
maintain the entire system up to the desired level of functioning. Hence, the
component having the large downtime assigned to be more critical.

21.  3.2.5 Safety impact While identifying the critical component of any system,
safety impact is of great concern. This criterion is classified into three sub-
criteria, human safety, resources safety, and environment safety. In case of a
manufacturing system, human and resource safety have significant roles while
environment safety also needs to be considered because of cooling systems.
The increasing requirements of maintenance in the unproductive use phase of
the product lifecycle of manufacturing systems produce a significant impact
on the environment as the defective parts; used oils, grease and cleaning
agents are discarding into the environment. If any accidents happen during
any process, it will directly affect the human beings. Hence, the safety factor
considered, while performing the criticality analysis of any system

22.  HOW TO INITIATE RCM
 1.Develop a Master equipment list identifying the equipment in your facility.
 2.Prioritize the listed components based on importance or criticality to operation,
process .Assign components into logical groupings.
 3.Types of Maintenance Programs
 4.Determine the type and number of maintenance activities required and periodicity
using:
 a. Manufacturer technical manuals.
 b. Machinery history.
 c. Root cause analysis findings - Why did it fail?
 d. Good engineering judgment.
 5.Assess the size of maintenance staff & Identify tasks that may be performed by
operations maintenance personnel.
 6.Analyze equipment failure modes and impacts on components and systems.
 7.Identify effective maintenance tasks or mitigation strategies.

23. Root Cause Analysis
 A root cause is the fundamental cause, which, if corrected, will prevent
recurrence of this and similar events. This is usually not a barrier/ control
problem but a weakness or defi ciency in the identifi cation, provision or
maintenance of the barriers/controls or the administrative functions.
 A root cause is ordinarily control-related involving such upstream elements as
management and administration. In any case, it is the original or source
cause.