This document discusses reliability-centered maintenance (RCM). It defines RCM as a corporate maintenance strategy that aims to optimize maintenance programs by preserving system functions through identifying failure modes and selecting effective tasks to control failures. The document outlines the history and principles of RCM, describing the classical and streamlined approaches. It provides an overview of the basic RCM process, which involves preparation, analysis, task selection, comparison, and record keeping. The advantages of RCM include lowering costs and minimizing failures, while disadvantages include startup costs and challenges dealing with hidden failures.
On the nature of FMECA... An introductionMartGerrand
Here's a presentation on Failure Modes, Effects and Criticality Analysis (FMECA) I did a few years ago, so the references may be truly historical. It's for educational use only - not for resale - so just enjoy!
On the nature of FMECA... An introductionMartGerrand
Here's a presentation on Failure Modes, Effects and Criticality Analysis (FMECA) I did a few years ago, so the references may be truly historical. It's for educational use only - not for resale - so just enjoy!
CBM Requirements by Carl Byington - PHM Design, LLCCarl Byington
Carl Byington with PHM Design, LLC reviews:
Conceptual functional architecture:
Describes functions and functional interactions
Traces functions to capabilities or services desired in the COO
Conceptual physical architecture:
Allocates and describes the conceptual implementation of functions
Traces implementation to function
Activity Flows:
Identifies primary paths through the principal use-cases to meet the goals and interests of the stakeholders
Trades identify preferred path which, in turn, provides context for requirements derivation and operational thread development.
#phmdesign
https://phmdesign.com
CBM Cost Benefit Analysis by Carl Byington - PHM Design, LLCCarl Byington
Carl Byington with PHM Design, LLC reviews some of the elements of CBM Cost Benefit Analysis. The analysis consider implementation and non recurring engineering cost as well as deferred, eliminated scheduled maintenance, reduced unscheduled maintenance, and operational cost savings drivers. Specific examples from aircraft, ground vehicle, and industrial applications are provided.
#phmdesign
https://phmdesign.com
Series of six rating sheets to provide a high-level, subjective evaluation of the design of various elements of a Human Performance Engineering Program. Sheet #1 is for the Conduct of Operations (ConOps) program.
Introduction to integrated vehicle health managementAndrew Heaton
A short introduction to Integrated Vehicle Health Management (IVHM). The ten-minute presentation covers the origins, basics concepts, customer propositions to IVHM & a case study about Rolls Royce's engine health management.
Reliability Centred Maintenance is a process used to determine what must be done to ensure that any physical asset continues to fulfil its intended functions in its present operating context.
Carl Byington has over thirty years developing models and analyzing data from various equipment and critical assets. He is currently a consultant who leads PHM Design, LLC, based in the greater Atlanta area. One operational strategy Carl Byington employs involves condition-based maintenance (CBM). This protocol rests on the concept that equipment failure is a process, rather than one single event.
Condition-based maintenance (CBM) is a philosophy of performing maintenance on a machine or system only when there is objective evidence of need or impending failure. By contrast, time-based or use-based maintenance involves performing periodic maintenance after specified periods of time or hours of operation. CBM has the potential to decrease life-cycle maintenance costs (by reducing unnecessary maintenance actions and greater operational failures), increase operational readiness, and improve safety.
Implementation of condition-based maintenance involves predictive diagnostics (i.e., diagnosing the current state or health of a machine and predicting time to failure based on an assumed model of anticipated use). CBM and predictive diagnostics depend on multisensor data—such as vibration, temperature, pressure, and presence of oil debris—which must be effectively fused to determine machinery health.
This presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
CBM Requirements by Carl Byington - PHM Design, LLCCarl Byington
Carl Byington with PHM Design, LLC reviews:
Conceptual functional architecture:
Describes functions and functional interactions
Traces functions to capabilities or services desired in the COO
Conceptual physical architecture:
Allocates and describes the conceptual implementation of functions
Traces implementation to function
Activity Flows:
Identifies primary paths through the principal use-cases to meet the goals and interests of the stakeholders
Trades identify preferred path which, in turn, provides context for requirements derivation and operational thread development.
#phmdesign
https://phmdesign.com
CBM Cost Benefit Analysis by Carl Byington - PHM Design, LLCCarl Byington
Carl Byington with PHM Design, LLC reviews some of the elements of CBM Cost Benefit Analysis. The analysis consider implementation and non recurring engineering cost as well as deferred, eliminated scheduled maintenance, reduced unscheduled maintenance, and operational cost savings drivers. Specific examples from aircraft, ground vehicle, and industrial applications are provided.
#phmdesign
https://phmdesign.com
Series of six rating sheets to provide a high-level, subjective evaluation of the design of various elements of a Human Performance Engineering Program. Sheet #1 is for the Conduct of Operations (ConOps) program.
Introduction to integrated vehicle health managementAndrew Heaton
A short introduction to Integrated Vehicle Health Management (IVHM). The ten-minute presentation covers the origins, basics concepts, customer propositions to IVHM & a case study about Rolls Royce's engine health management.
Reliability Centred Maintenance is a process used to determine what must be done to ensure that any physical asset continues to fulfil its intended functions in its present operating context.
Carl Byington has over thirty years developing models and analyzing data from various equipment and critical assets. He is currently a consultant who leads PHM Design, LLC, based in the greater Atlanta area. One operational strategy Carl Byington employs involves condition-based maintenance (CBM). This protocol rests on the concept that equipment failure is a process, rather than one single event.
Condition-based maintenance (CBM) is a philosophy of performing maintenance on a machine or system only when there is objective evidence of need or impending failure. By contrast, time-based or use-based maintenance involves performing periodic maintenance after specified periods of time or hours of operation. CBM has the potential to decrease life-cycle maintenance costs (by reducing unnecessary maintenance actions and greater operational failures), increase operational readiness, and improve safety.
Implementation of condition-based maintenance involves predictive diagnostics (i.e., diagnosing the current state or health of a machine and predicting time to failure based on an assumed model of anticipated use). CBM and predictive diagnostics depend on multisensor data—such as vibration, temperature, pressure, and presence of oil debris—which must be effectively fused to determine machinery health.
This presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
When working for Petrobras at PRSI (Pasadena Refining System Inc.) I had this opportunity to share my experience as a Maintenance Manager in Brazil with PRSI operators and maintenance crew.
Reliability-Centered Maintenance. An introduction to by JBMmartinjib
Reliability is of a great interest for me because I studied it during my MSc. of Eng. and because I do believe in it: "a reliable asset is a safe asset"...
One of the many ways to improve the reliability of an asset is to implement a Reliability-Centered Maintainance.
Reliability-centered maintenance (RCM) & Total Productive Maintenance (TPM).pptxSamuel Gher
Two effective theories for maximising equipment care are Reliability-Centered Maintenance (RCM) and Total Productive Maintenance (TPM). Using a data-driven methodology, RCM assigns specific maintenance activities based on the prioritisation of important equipment and the analysis of possible breakdowns. Imagine it like a specialised physician locating and treating particular weak points. TPM, on the other hand, uses employee engagement to promote a continuous improvement culture. Everyone assumes responsibility for maintaining the equipment, from operators doing routine upkeep to quality specialists identifying the underlying causes of defects, much like a well-trained team. Both strive for maximum equipment efficiency, while TPM places more emphasis on cultural change and RCM emphasises accuracy. The best strategy for you will rely on your unique requirements. TPM works best with widespread participation, while RCM excels with vital equipment. In the end, integrating these ideas can result in a really strong
Definition of RCM, principles and goals of RCM; Four major components of RCM: reactive maintenance, preventive maintenance, predictive testing and inspection and proactive maintenance; RCM strategies.
The preventive maintenance program is developed using a guided logic approach and is task oriented rather than maintenance process oriented. This eliminates the confusion associated with the various interpretations across different industries of terms such as condition monitoring, on condition, hard time, etc. By using a task oriented concept, it is possible to see the whole maintenance program reflected for a given item. A decision logic tree is used to identify applicable maintenance tasks. Servicing and lubrication are included as part of the logic diagram as this ensures that an important task category is considered each time an item is analyzed.
Maintenance Program Content
The content of the maintenance program itself consists of two groups of tasks.
• A group of preventive maintenance tasks, which include failure-finding tasks, scheduled to be accomplished at specified intervals, or based on condition. The objective of these tasks is to identify and prevent deterioration below inherent safety and reliability levels by one or more of the following means:
o Lubrication/servicing;
o Operational/visual/automated check;
o Inspection/functional test/condition monitoring;
o Restoration;
o Discard.
It is this group of tasks, which is determined by RCM analysis, e. it comprises the RCM based preventive maintenance program.
• A group of non scheduled maintenance tasks which result from:
• Findings from the scheduled tasks accomplished at specified intervals of time or usage;
• Reports of malfunctions or indications of impending failure (including automated detection).
The objective of this second group of tasks is to maintain or restore the equipment to an acceptable condition in which it can perform its required function.
An effective program is one that schedules only those tasks necessary to meet the stated objectives. It does not schedule additional tasks that will increase maintenance costs without a corresponding increase in protection of the inherent level of reliability. Experience has clearly demonstrated that reliability decreases when inappropriate or unnecessary maintenance tasks are performed, due to increased incidence of maintainer-induced faults.
Continued...
Maintenance is important in any organization. Without proper maintenance, assets deteriorate over time reducing the quality of your output produced. It can also impact the safety of your asset or your people who operate it. Asset management focuses on assuring your people that parts and processes are optimized to improve asset performance. Reducing inventory, maintenance costs and the number of downtime events raises your productivity, while simultaneously driving financial performance and predictability. It also helps your employees with the right tools to make good decisions about driving your plant performance.
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Boost Equipment Performance, Save Money With Proactive MaintenanceJames Fitzgerald
Proactive, timely maintenance of plant equipment is critical to enabling manufacturers to meet a dizzying number of demands, from pressure to achieve target output levels, minimize labor costs, control parts spending and ensure maximum uptime. Manufacturers rely on their maintenance departments to help achieve these goals on a daily basis. However, a great number of manufacturers still use maintenance on a reactive basis rather than viewing it as strategic to operations. Myrtle Consulting helps manufacturers convert maintenance into a proactive, scheduled operation that is used strategically to control costs, maximize uptime, and maintain critical equipment. By following a few fundamental principles, plants can begin to establish a maintenance improvement program that supports operations and improves plant performance.
Engineered Maintenance by Waqas Ali Tunio
Presented by me in subject of Maintenance Engineering, in my 8th semester of Mechanical Engineering of 2007-Mechanical Batch on 3rd Nov, 2010.
Department of Mechanical Engineering,
Quaid-e-Awam University of Engineering, Science & Technology, Nawabshah - Pakistan
www.aliwaqas.tk
Much has been written about lean manufacturing and the lean enterprise—enough that nearly all readers are familiar with the concepts as well as the phrases themselves. But what about lean maintenance?
Is it merely a subset of lean manufacturing? Is it a natural fall-in-behind spinoff result of adopting lean manufacturing practices?
Much to the chagrin of many manufacturing companies, whose attempts at implementing lean practices have failed ignominiously, lean maintenance is neither a subset nor a spinoff of lean manufacturing. It is instead a prerequisite for success as a lean manufacturer. This article will explain why.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
AKS UNIVERSITY Satna Final Year Project By OM Hardaha.pdf
RELIABILITY CENTERED MAINTAINANCE
1. CECOS University Of IT and Emerging Sciences
Peshawar
Mechanical Department
TOPIC:RELIABILITY,CENTRED MAINTENANCE RELIABILITY
By:kifayat ullah
Email:kifayatullah318@gmail.com
2. Reliability
Reliability is a measure of the probability that an item will perform its intended function for a
specified interval under stated conditions. There are two commonly used measures of
reliability:
* Mean Time Between Failure (MTBF), which is defined as: total time in service / number of
failures
* Failure Rate (λ), which is defined as: number of failures / total time in service.
Reliability centeredmaintenance:
Definition: Reliability centered maintenance (RCM) is a corporate-level maintenance strategy
that is implemented to optimize the maintenance program of a company or facility. The final
result of an RCMprogram is the implementation of a specific maintenance strategy on each of
the assets of the facility. The maintenance strategies are optimized so that the productivity of
the plant is maintained using cost-effective maintenance techniques.
There are four principles that are critical for an reliability centered maintenance program.
1. The primary objective is to preserve system function.
2. Identify failure modes that can affect the systemfunction.
3. Prioritize the failure modes.
4. Select applicable and effective tasks to control the failure modes.
RCM History:
1965: Studies show scheduled overhaul of complex equipment has little or no effect on in-
service reliability
1970: RCM had its beginning in the commercial airline sector in 1970's. At that time, the
commercial airline industry was experiencing high number of crashes in the take-offs which
majority of them was related to equipment failures
After applying the RCM method, it proved to be highly successful; in commercial airlines it
reduced crashes from 60 per million take-offs to only 2 per million and more important than
that reduced the equipment related crashes from 40 per million to only 0.3 per million take-
offs.
3. Types of RCM:
There are different ways to conduct and implement an RCMprogram;
Classical/Rigorous
Classical or rigorous RCM provides the most knowledge and data concerning system
functions, failure modes, and maintenance actions addressing functional failures of any of
the RCM approaches.
Intuitive/Streamlined/Abbreviated
The intuitive approach identifies and implements the obvious, usually condition-based,
tasks with minimal analysis. In addition, it culls or eliminates low value maintenance tasks
based on historical data and Maintenance and Operations (M&O) personnel input.
The Principles of RCM:
• RCM is Function Oriented.
• RCM is System Focused
• RCM is Reliability-Centered
• RCM Acknowledges Design Limitations
• RCM is Driven by Safety, Security, and Economics
• RCM Defines Failure as "Any Unsatisfactory Condition
• RCM Uses a Logic Tree to Screen Maintenance Tasks.
• RCM Tasks Must Be Applicable
• RCM Tasks Must Be Effective
• RCM Acknowledges Three Types of Maintenance Tasks :
o Time directed (PM)
o Condition directed (CM)
o Failure finding (Proactive Maintenance)
• RCM is a Living System
The RCM Process –Basic Steps:
RCMis nota stand-alone process,itmustbe an integral partof the Operationsand
Maintenance program.the followingstepcanbe define asfollows.
Preparation
The preparatory phase has a number of steps which basically involve the selection of the
systems to be analysed, gathering the necessary data for the analysis. In addition the ground
rules or criteria to be used in the selection and analysis process must be established. The stages
can be summarised as follows:
4. System Selection.
Definition of the system boundaries.
Acquisition of Documentation and Materials.
Interviews with Plant Personnel.
Analysis
Once the systems have been selected for analysis and the preparations have been completed
the analysis can commence. Experience in the analysis process is important for effective
decision-making. Such experience may exist in the utility or it may be bought in from specialist
service providers in this area. The analysis involves the following stages.
Identificationof SystemFunctions
SystemFunctional failure analysis
Equipmentidentification
ReliabilityandPerformance Datacollection
Identificationof failure modes
Identificationof failure effects
Determinationof ComponentCriticality
Task Selection
The task selection process uses various forms of logical decision making to arrive
at conclusions in a systematic manner. The outcomes can include:
Preventive maintenance
Condition monitoring
Inspection and functional testing
Run to Failure
Task Comparison
When the task selection has been completed and reviewed, the recommendations arising
from the task selection process will be compared against the current maintenance practices.
The purpose of this comparison is to identify the changes needed to the maintenance
programme and the impact on resources and other commitments.
5. Task Comparison Review
The outputs of the analysis will result in a change to the maintenance programme. It is
important that such changes are consistent with the maintenance philosophy of the plant and
with regulatory and social obligations. For this reason it is important that the process and its
outcomes be subjected to a final review.
Records
RCM should form part of a living programme. The outcomes of the analysis process and the
implementation of the recommendations will have an impact on the effectiveness of the
operations and maintenance programmes. It is important therefore, that all decisions, the basis
for them and those involved in making them are effectively recorded, so that the information is
available to those carrying out subsequent reviews of the maintenance strategy.
ADVANTAGES
Can be the most efficient maintenance program.
Lowers costs by eliminating unnecessary equipment maintenance or system overhauls.
Minimizes the frequency of overhauls.
Reduces probability of sudden equipment failures.
Focuses maintenance activities on critical system components.
Increases component reliability.
Incorporates root cause analysis.
DISADVANTAGES
Can have significant startup costs associated with staff training and equipment needs
Savings potential is not readily seen by management.
RCM is not cheap; it imposes many accomplishing costs to system, for example training
costs and costs of employing some new experts for replacement with those who
entered in the program and have not enough time to fulfill their responsibilities as
before.
Dealing with hidden failures causes challenges for many analysts (and then others) not
familiar with the concept
6. Reliability-CenteredMaintenanceMethodology
Reliability-centered maintenance (RCM) is the optimum mix of reactive, time or interval-based,
condition-based,andproactive maintenance practices. These principal maintenance strategies, rather
than being applied independently, are integrated to take advantage of their respective strengths in
order to maximize facility and equipment reliability while minimizing life-cycle costs.
Total productive maintenance (TPM), total maintenance assurance, preventive maintenance, relia-
bilitycenteredmaintenance (RCM),andmanyotherinnovative approachestomaintenance problems all
aim at enhancing the effectiveness of machines to ultimately improve productivity
Reliability-CenteredMaintenanceComponents
The components of RCM program are shown in Figure 1. This figure showing that RCM program consists of
(reactive maintenance, preventive maintenance, condition based maintenance, and proactive maintenance)
and its patterns.