Lrrcm Analysis Process


Published on


Published in: Technology, Business
1 Like
  • Be the first to comment

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

Lrrcm Analysis Process

  1. 1. Reliability-Centered Maintenance Analysis A Description of the RCM Process and an Explanation of the Reports A Description of The RCM Analysis Process consists of seven clearly defined steps the RCM Process that lead an analyst to the conclusions of the best maintenance strategy for a particular asset or system. These seven steps are summarized here, and described in more detail below. • Gather and document basic information about the asset • Perform a failure modes and effects analysis (FMEA) • Identify potential risks and consequences of failure • Determine maintenance actions for mitigating risk • Generate a cost-benefit analysis and justify recommendations • Compile the results and generate draft documents for review • Incorporate review comments and generate a final report Preliminary Step Prior to performing the analysis, it is necessary to select the -------------------------------- system to be analyzed. Each organization will have their own Select System for Analysis approach for making these selections, and usually the factors that are considered include past history of failure, economic impact as a result of failure, availability of information, and the availability and experience of the analysis team with respect to the individual asset or system. Because there is such an abundance of equipment, and typically so few people to perform analysis work, it is vital that this selection process be conducted carefully. _____________________________________________________ Software Tools to Support While it is possible to document this process in simple word the RCM Process documents or spreadsheets, the premier tool for performing this -------------------------------- analysis is RCM Strategy Plus™. The use of this tool enables the RCM Strategy Plus™ following benefits: • consistent sharing of information between all agency centers, including subcontractors, • extensive knowledge base of equipment analyses, • conformance to approved RCM methodologies, • advanced techniques for assessing risk and potential consequences of failure, • integration with CMMS and on-line monitoring and expert diagnostic tools, and • automatic generation of reports. RCM Analysis Process Page 1
  2. 2. Reliability-Centered Maintenance Analysis Graphical View of the RCM Process Define Boundaries Gather Information and Describe Operating Context Generate Basic System and Document Equipment and Nameplate Data Œ Step Equipment Information Describe General History Describe References Generate Basic Information Describe Codes and Regulations Perform Failure Modes and Identify Functions and performance criteria • Step Effects Analysis (FMEA) Identify Failure Modes Identify Failure Causes Generate FMEA Identify Failure Effects Identify Potential Risks and Define Seriousness and Likelihood of Failure • For Every Failure Cause Consequences of Failure Ž Step • For All Defined Risk Criteria Use Risk Matrix Identify Hidden Failures Determine Maintenance Actions Determine Maintenance Tasks (CM,TD,FF) Step • for Mitigating Risk Determine Optimum Frequency for Tasks Determine Policy Requirements Decision Support Diagram Identify Redesign Requirements Generate Cost-Benefit Analysis and Justify Recommendation Step • Perform Cost - Benefit Analysis Cost - Benefit Analysis Compile Analysis Results into Prepare Executive Summary Draft Documents for Review ‘ Step Generate Summary Reports Generate Detail Reports Generate Draft Reports Technical/Management Review Review Technical Strategy Issue Final Reports Review Cost-Benefit Analysis Define Implementation Strategy ’ Step Incorporate Review Adjustments Review Generate Final Reports Generate Implementation Strategy Generate Final Reports RCM Analysis Process Page 2
  3. 3. Reliability-Centered Maintenance Analysis Step Œ This step gathers and starts documenting basic information Basic Information about the system being ana lyzed. By understanding the process fluid flow from a Piping and Instrumentation Diagram (P&ID) or diagrams and electrical schematics, it is possible to establish boundaries and identify the equipment that is contained within those boundaries. It is then necessary to describe and document certain basic information about the system that will be instrumental in developing the ultimate maintenance strategy for that system. The basic information that must be generated for the system includes the following: • Equipment Boundaries, • Operating Context, • Equipment Nameplate Data, • General History about the System and Equipment, • References that will be helpful in performing the analysis, such as: operator manuals, maintenance manuals, drawings, diagrams and schematics, codes and regulations, photographs, and other miscellaneous references. Step • This step defines and describes all of the possible ways that the Perform a Failure Modes system can fail, and drills down to specific causes leading to those and Effects Analysis failures and their associated effects. The process of generating (FMEA) FMEA’s first defines the functions of the system, which then leads to identifying the modes by which the system can fail to provide those functions. The specific mechanisms by which those modes of failure occur are called failure causes. The final step in the FMEA analysis is to describe the “effects” of failure, which are the physical events that take place when the failure happens. Step Ž This step determines why each failure cause matters. It evaluates Identify Consequences of the seriousness of the failure with the likelihood that the failure Failure using a Risk will occur. The result is the rank of potential risk or consequence Matrix associated with that failure cause. In order to be comprehensive in the analysis, evaluation criteria typically considers such factors as personnel safety, public health and environmental issues, economic factors, foregone revenues associated with lost opportunity, maintenance cost, and impact to mission. Each failure cause is ranked into common categories of risk (i.e. high, medium, low, no). User organizations are able to define their own categories and use their customized terminology. RCM Analysis Process Page 3
  4. 4. Reliability-Centered Maintenance Analysis Step • This step uses a decision support diagram to determine the best Determine Maintenance maintenance actions for mitigating the risk associated with each Actions for Mitigating and every failure cause. In addition to identifying hidden failures, Risk using a Decision this step will also determine policy requirements, and when there Support Diagram are no cost effective and applicable actions that can mitigate risk, it will identify redesign requirements as the last opportunity for creating an acceptable situation. When the potential risk of failure is acceptable and there are no cost effective actions, there will be many times that a “run-to-failure” philosophy will be the recommended approach. The types of actions that are identified by the Decision Support Diagram include the following: • Time Directed (Health Restorative) • Condition Monitoring • Condition Directed • Failure Finding • Training Program • Administrative Policies or Procedures • Redesign • No Scheduled Maintenance (Run-To-Failure) Determine Task This step determines the best fr equency by which to perform the Frequency maintenance actions identified in the above process. There are several methods by which this frequency can be determined. If the task is associated with a hidden failure, then there are mathematical equations that will help calculate this frequency. For all other tasks, the user must understand the nature of the failure as it pertains to a common degradation curve (often known as the P-F curve) in order to make the best frequency judgment. There are advanced reliability calculations that can be performed associated with failures for which accurate failure and consequence data is available. These advanced reliability calculations normally only apply to a very small number of equipment. Regardless of the method used for determining the frequency of the recommended action, the analyst should document the reasoning behind the entire decision support process and how the frequency was determined. The Failure Analysis Report displays this information. RCM Analysis Process Page 4
  5. 5. Reliability-Centered Maintenance Analysis Step • This step provides justification for the resulting recommendations. Generate a Cost Benefit It compares the cost of performing the maintenance actions with Analysis the translated cost of risk to arrive at a financial benefit. This cost- benefit analysis provides an excellent tool supporting the decision making process for approving the recommendations. Step ‘ This step generates the package of reports that a review team uses Compile Results and to review all of the analysis information for technical content, Generate Draft Reports financial impact, and ability to implement. It also includes an For Review executive summary which highlights the key information of the analysis. Step ’ This step incorporates all of the comments and necessary Final Report adjustments from the previous step and generates a final, complete package of reports. Accompanying this final report should be a description of how the analysis was created and a plan for implementation. Explanation of The entire set of reports for this analysis consists of 16 Reports individual reports, compiled into one comprehensive package. The reports are organized into the following categories: Overview Reports • Executive Summary Report Operating Context and Support Information • Operating Context Report • Analysis Boundaries Report • General History Report • Codes / Regulations Report Analysis Reports Failure Summary • Failure Modes and Effects (FMEA) Tree Report • Functions and Failure Modes Report Failure Details • Decision Support Diagram Response Summary Report • Failure Analysis Report Maintenance Action Information • Summary of Maintenance Costs vs. Task Costs Report • Summary of Maintenance Actions by Frequency report • Summary of Maintenance Actions by Skill Code Report • Details of Maintenance Actions Report Appendices • Drawings, diagrams and Photographs Report • Risk Matrix Report • List of Abbreviations Report RCM Analysis Process Page 5
  6. 6. Reliability-Centered Maintenance Analysis Executive Summary This report provides a high level summary of the project and the analysis. It describes the team of people involved in the project, the objective of the analysis, the scope of the analysis, a summary of the results of the analysis, a summary of the recommendations, a summary of the benefits associated with executing the recommendations, and a description of the proposed implementation plan. Operating Context This report provides a description of the operating context Report associated with the asset or system. It may also include a description of the operating context of the hierarchical elements above the asset or system being analyzed, such as the building, area, plant or organization that is associated with this system. General History This report provides a description of any known failures and Report degradation issues with the system or asset. It also includes any pertinent information that should be documented with the analysis such as age of the equipment, operating behavior of the equipment, and unique characteristics that should be documented, or anything else that the analyst feels may be of value that contributes to an improved understanding or current of past performance. Codes / Regulations This report provides a description of all known codes and Report regulations that should be documented which contribute toward decisions associated with the recommendations. Such codes and regulations should include federal, state, regional, municipal, and local as well as any internal organizational policies and procedures. OSHA and DOT and other related codes and regulations should also be included in this report. Failure Modes and This report provides a summary of the functions, failure modes Effects (FMEA) and failure causes of the analysis. It also displays the risk ranking Tree Report results of each failure cause. Functions and Failure This report provides a detailed description of the functions, Modes Report failure modes and failure causes. It includes a numbered listing of each item so that they can easily be referenced throughout the entire package of reports. Decision Support This report provides a single page tabulation of the responses Diagram Response that were documented for each failure cause while navigating Summary Report through the Decision Support Diagram. It also provides a graphical display of the Decision Support Diagram itself. This report provides an appreciation for the overall flavor of the types of maintenance action recommendations that were made for the analysis. RCM Analysis Process Page 6
  7. 7. Reliability-Centered Maintenance Analysis Failure Analysis This report provides a description of the maintenance action Report recommendations that are made for each failure cause, as well as documenting all of the Decision Support Diagram responses. In addition, the report includes any comments associated with why or how the Decision Support Diagram responses were made, as well as the frequency of the recommended maintenance action and any justification related to those frequency selections. Summary of Failure This report provides a description of the risk mitigated and the Costs vs. Task Costs benefit achieved as a result of the recommended maintenance Report actions. It shows specifically which category of risk is mitigated, and it provides a dollar savings associated with that mitigation. It also shows the cost of performing the maintenance actions in order to generate an entire savings associated with each and every failure cause. Summary of Maintenance This report provides a summary of all the maintenance actions that Actions by Frequency are recommended. The actions are organized by frequency, and Report for each action, it shows all the failures causes that are associated with that action. Summary of Maintenance This report provides a summary of all the maintenance actions that Actions by Skill Code are recommended. The actions are organized by the skill code that Report they are assigned to. Details of Maintenance This report provides the details of each of the recommended Actions Report maintenance actions. Drawings, Diagrams and This report provides a printout of any drawings, diagrams, Photographs Report photographs, or any other digitally captured file or document associated with the asset or system. Risk Matrix Report This report provides a description of the entire configuration of the risk matrix. It includes all definitions of seriousness, likelihood of failure, definitions of risk, and details about the risk matrix itself. List of Abbreviations This report provides a listing and reference of the all the Report abbreviations that are used in the entire package of reports. RCM Analysis Process Page 7