This document discusses reliability centered maintenance (RCM) and its implementation at Boeing. It provides background on Boeing and describes RCM's focus on identifying maintenance policies to manage equipment failure risks. The document outlines how Boeing initially used RCM in 1969 but then discusses reasons for failures in Boeing's 787 fleet, such as over-reliance on outsourcing. It concludes by suggesting improvements like monitored outsourcing, focusing on condition monitoring and predictive maintenance using RCM.

1. RELIABILITY CENTERED
MAINTENANCE
WHAT WENT WRONG WI TH BOEING
Presented By –
Aman Rawat (07304), Ankit Goyal (07305), Ashlesh Sonkusare
(07310), Nandhagopal Muralithar (07335)

2. WHAT IS BOEING
• An American multinational corporation.
• It designs, manufactures, and sells fixed-wing aircraft,
rotorcraft, rockets and satellites.
• It is among the largest global aircraft manufacturers.
• It is the second-largest aerospace & defence contractor in the
world based on 2012 revenue.
• Boeing Company's corporate headquarters are located
in Chicago.

3. INTRODUCTION TO BOEING
• Revenue in 2012 – US $ 81.7 billion
• One of the largest US exporters
• Customers and in 150 countries
• 0.17 million employees in 70 countries.
• 2 Business Units
Boeing Commercial Planes
Boeing Defense Space and Security

4. RELIABILITY CENTERED MAINTENANCE
• It is an industrial improvement approach focused on
identifying and establishing the operational, maintenance
and capital improvement policies that will manage risks of
equipment failure most effectively.
Determine the
maintenance
requirements of
machinery
Develop cost effective
and planned
maintenance
programs
Design process to
obtain life expectancy
of component

5. RELIABILITY CENTERED MAINTENANCE
• Objectives of RCM:
Minimum Cost
Safety of system
Reliability i.e. avoid risk of failure
• RCM 2 – 1983
Objective - To improve the consequence rather than just
failure avoidance.

6. IMPLEMENTATION OF RCM AT BOEING
• Year 1969
• RCM was used to analyze the causes, impact remedies for
asset failure and taking preventive action to minimize
failure rates throughout operation.
• Maintenance Performance Toolbox is one of the key
Boeing solutions have to help airlines.
• RCM focus on
Failure analysis
Consequence analysis
Task analysis

7. APPLICATION OF RCM AT BOEING
• Health Monitoring Systems
Allow airplane to self monitor and report maintenance requirements
to ground based computer systems.
• Mobile Application
Mobile Applications were used for schedule maintenance and faster
detecting aircraft issues (Toolbox Mobile Parts, Maintenance turn
time)
Simultaneously, improvement in real time regulations, decrease
flight delays and reduce operational expenditures can be handled.

8. APPLICATION OF RCM AT BOEING
• RFID (Radio Frequency Identification)
RFID Systems automated maintenance task on Emergency
equipment Management, Rotables Management, Repairable
Management, Structural Repair, Essential Cabin Items etc.
RFID enabled process were used to check security and servicability,
independently or simultaneously.

9. REASONS FOR FAILURE AT BOEING
• Failure of the Boeing 787 fleet
• Tried to save costs related to providing on-site
quality, supplier management and technical
support by outsourcing them
• Outsourced 70% compared to 35-50% for 737 & 747
• Had to send its engineers to sites of various Tier-1, 2
& 3 suppliers worldwide to solve the technical
problems

10. REASONS FOR FAILURE AT BOEING
• Extra risk in dealing with lengthy supply chain, and
cultural and language differences with suppliers
• Important especially when the team did not have members
with expertise on supply chain risk management
• Technical problems – overheating batteries, glitches
with brakes, hydraulic pumps, power issues and ice
forming in engines
• Results of failure – lower reliability; higher
maintenance costs; falling reputation of the
company

11. SUGGESTIONS
• Change in focus from complete outsourcing to
monitored outsourcing of parts
• Fundamental change in focus from failure assessment
based on age to “memoryless” exponential probability
distribution
• Effort to be focused on process on failure than
predicting life expectancy
• Equal focus on user requirements and design reliability
• Focus on condition monitoring and predictive
maintenance
• Linking levels of tolerable risk to maintenance strategy
development

12. SUGGESTIONS
• Finding root cause without resorting to redesign all
the time
• Don’t be afraid of short term solutions, but always
have long term plan for defect elimination
• Infant mortality and unknown failure risk high in
redesign
• RCM can be used to mitigate defects while also
working on risks associated with maintenance
measures.

13. THANK - YOU