Reliability Centered Maintenance Made Simple

RCMBlitzTM

RCM Made Simple

Introduction to RCM Blitz™

Presented by:
Doug Plucknette
World-Wide RCM Discipline Leader What would you do with more
free time?
GPAllied

Copyright 2008 Allied Reliability, Inc.

RCMBlitzTM

Welcome to our RCM Blitz™!

“When it comes to building a complete maintenance
strategy that will achieve and maintain the inherent
designed reliability of an asset, there is no other tool
available that has the success record of traditional RCM.”

Doug Plucknette
Reliability Centered Maintenance
Using… RCM Blitz


RCMBlitzTM

Specific Benefits of Applying the RCM to
Your Process
Y P
Your Company will be able to develop a
complete maintenance strategy for your
equipment that includes clearly written and
precise preventive and predictive
maintenance tasks

Your Company will be able to put into place
failure-finding tasks that will reduce the
g
probability of catastrophic HSE (Health,
Safety, Environmental) failures


RCMBlitzTM

Specific Benefits of Applying the RCM
Method to Your Process, cont’d
M th d t Y P t’d
Your Company will learn how to reduce MTTR
(Mean Time To Restore) through the use of
Consequence Reduction Tasks
Your Company will be able to determine the
spare parts that need to be stored on site
and the parts that can stored by a vendor
Your Company will learn how to identify where
to apply the RCM Blitz™ process based on
pp y p
Reliability Measures


RCMBlitzTM

M th d t Y P t’d
• Reduce Emergency/Demand maintenance work
• Reduce maintenance costs by reducing
secondary equipment damage
• Reduce unit cost of product by lowering
maintenance costs and improving Overall
Equipment Effectiveness (OEE)
q p ( )
• Increase the understanding of how your
equipment is supposed to work for both
operations and maintenance people
ti d i t l


RCMBlitzTM

M th d t Y P t’d
Develop a detailed and effective
troubleshooting guide based on actual failure
alarms, effects and symptoms
Develop detailed operations checklists to
ensure proper set-up and operation of
equipment - (What would the reliability of the
airline industry be without checklists?)
Learn how to apply the RCM process to new
pp y p
equipment designs


RCMBlitzTM

Why Does the RCM Method Work?
• RCM adds the right amount of structure and discipline
to the expert knowledge of your people
• The finished product is a complete maintenance
strategy based on predicting, preventing and
eliminating specific Failure Modes
• The airline industry has a proven record of reliability
and safety yet their maintenance cost per replacement
value is lower than most manufacturing maintenance
l i l th t f t i i t
• The big difference is leadership, structure and
discipline


RCMBlitzTM

Section 1 RCM History

RCMBlitzTM

What would you do with more
free time?


RCMBlitzTM

The History of RCM
• US DOD and United Airlines

• Utilities Industry

• Manufacturing

• Commercial Standards for RCM
– SAE J1011
– PASS55


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Various Approaches to RCM
• Traditional – SAE J1011
– 7 Steps
p

• Streamlined

• PMO


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Section 4 RCM Maintenance
St ateg es
Strategies
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Maintenance Tasks
• The key to ensuring the designed reliability
of your process is selecting the correct
y g
maintenance task to address a specific
failure mode or cause of failure


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Maintenance Tasks, cont’d
In RCM we have 5 types of maintenance tasks

1. On-condition Maintenance
2.
2 Preventive Maintenance
3. Failure Finding
4.
4 Redesign
5. Run to Failure


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On-Condition Maintenance
A maintenance task that is put into place to
detect failure resistance to a specific failure
mode

The detection of failure is based on a known
potential failure condition


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Traditional Types of On-Condition
Maintenance
M i t
• Vibration Analysis
• Thermography
• g
Ultrasonic Testing
• Tribology
• g
Non-Destructive Testing
• Motor Current Analysis
• Process Verification


RCMBlitzTM

Non-Traditional Types of On-Condition
Maintenance
M i t
• Human Senses


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How PdM Works – Early Identification of
Defects
D f t

P

F


RCMBlitzTM

Completing the P-F Curve
• RCM Reliability Centered Maintenance • Precision Alignment
• FMEA • Precision Balancing
• Design RCM Blitz • Installation Standards
• Five Rights of Reliability • Torque Specifications
• Precision Tools
• Select S
S l t Supplier Agreements
li A t
• Requirements Documents
• Design Standards

Reactive
Proactive Maintenance/Reliability Tasks PdM Tasks Maintenance
sistance to Failure

I Installation
t

P Potential Failure

F Functional
Res

I-P Interval Failure
P-F Interval

T - Time
The Modified P-F Curve and I-P Interval are intellectual property of Reliability Solutions, Inc. (Patent Pending)


RCMBlitzTM

Preventive Maintenance (PM) Tasks
• Preventive maintenance is time based, it is
performed on equipment that has a known
age or useful life
f l lif
• These tasks should be set up to prevent
failures on components that fit age based
failure patterns (A-C)
• Scheduled Inspection, Scheduled Rework
p ,
and Scheduled Discard are preventive
maintenance tasks


RCMBlitzTM

Failure Finding Tasks
Scheduled inspections of a hidden function
item, intended to find functional failures that
have already occurred but are not evident to
the operating crew

The objective of a failure finding task is to
ensure adequate availability of a hidden
function


RCMBlitzTM

Redesign
Any change in equipment, process, or
procedures

In order for a redesign to be considered
applicable and effective it must:

– Eliminate the failure
– Be cost effective
– Reduce the conditional probability of failure to an
acceptable level
– Change the function of an item from hidden to
evident


RCMBlitzTM

No Scheduled Maintenance
This becomes the maintenance strategy
when there is no applicable or effective task,
or no applicable or effective redesign

*When “No Scheduled Maintenance” is your
maintenance strategy, you must put in place a
consequence reduction strategy


RCMBlitzTM

Consequence Reduction Strategy
When no schedule maintenance is the only
remaining strategy, it becomes important to
g gy
make sure you have the proper spare parts,
resources and procedures in place to reduce
the
th consequence of th failure
f the f il


RCMBlitzTM

Pulling It All Together
So how is all of this accomplished?

Apply the RCMBlitz™ process to your equipment!


RCMBlitzTM

Section 5 The RCM Process

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RCMBlitzTM

The 7 Steps of Reliability Centered Maintenance
Traditional RCM Methodologies fit this 7-step process defined by
SAE standard JA1011:

1. What are the functions of the asset?
2. In what way can the asset fail to fulfill its functions?
3. What causes each functional failure?
4. What happens when each failure occurs?
5. What are the consequences of each failure?
6. What should be done to prevent or predict the failure?
7. What should be done if a suitable proactive task cannot be found?


RCMBlitzTM

The RCM Process
1. List the Process Functions
2. List the Functional Failures
3. List the Failure Modes and Probability of
Failure
4. Describe the Failure Effects
5. Determine Consequence Category
6. Run the Failure Mode through the RCM
Decision Process
7. Select a Maintenance Task and assess
spare parts
p p


RCMBlitzTM

Listing Functions
• Function
– The normal or characteristic actions of an item,
defined in terms of performance capabilities
– Point at which you actually begin your RCM
analysis
– Listing the system and component functions is a
key step in the RCM process
y p p
– The first function we list will be the System
Function or Main Function
– The System Function will clearly state what the
intent of the process is, and the performance
standards it is expected to maintain
p


RCMBlitzTM

Main Function
The Main Function or System Function
The reason the asset or process exists including
p g
the expectation of the process and performance
standards we need to maintain

Example Main Function
If you were about to analyze a process that made #2
pencils, your main function would be:

1.To b bl to
1 T be able t make #2 pencils at a rate of 1200 units per
k il t t f it
hour, while meeting all quality, safety, health, and
environmental standards


RCMBlitzTM

Main Function, cont’d
• Once you have listed the Main Function and
determined the performance standards, you
y
will move on to list all of the support
functions


RCMBlitzTM

Support Functions
Describe the functionality of each component within
the system
– The support function for fuel piping would be:
• To be able to contain and transport fuel
– The support function for a gear box would be:
• To be able to reduce RPM by a 4 to 1 ratio
– The support function for a E-Stop button would be:
• To be capable of shutting down the system in the event
of an emergency
– A support function for equipment structure would be:
• To be able to support the vessel


RCMBlitzTM

Hidden Functions
• Functions that will not be evident to the
operating crew under performance of their
g
normal duties
In a high level probe a hidden function would be:
To be capable of shuting down tank supply when it
reaches a set level

The function of this device during normal operations
of the system is not evident to the operator


RCMBlitzTM

Functional Failure
• Failure of an item to perform its normal
actions within specified performance
standards
• The functional failure is phrased as the
inverse of the function


RCMBlitzTM

Functional Failure, cont’d
There may be one or more functional failures
for every function
y
Main Function
1. To be able to make # 2 pencils at a rate of 1200
units per hour while meeting quality, health,
quality health
safety and Environmental standards
Functional Failure
1. 1. Unable to make #2 pencils at all
1. 2. Unable to make pencils at a rate of 1200 per hr
1. 3. Unable t
1 3 U bl to meet quality standards
t lit t d d
1. 4. Unable to maintain health, safety and
environmental standards


RCMBlitzTM

Failure Modes
The specific manner of failure; the
circumstances or sequence of events which
leads to functional failure

Should be written in a way that describes the Part,
Problem, and the Specific Cause of failure
• Fuel Pump Bearing (Part)
• Seized (Problem)
• Fails due to lack of lubrication (specific cause)
( p )


RCMBlitzTM

Failure Modes, cont’d
When listing Failure Modes you should
remember to include:
– All failure modes that have occurred
– All dominant failure modes
– Failure modes that are likely to occur
– Failure modes that have occurred on similar
equipment


RCMBlitzTM

Do Not List:

Failure modes that are highly unlikely to occur!


RCMBlitzTM

• When listing failure modes, be sure to write
them at root cause level

• Failure modes should be written at the level of
which you maintain the equipment


RCMBlitzTM

Failure Effects
The immediate physical effects of a
functional failure on surrounding items and
g
on the functional capability of the equipment

Failure Effects are the principal determinant
of failure consequences


RCMBlitzTM

Failure Effects, cont’d
Failure Effect statements should include:
– Events that lead up to the failure
p

– The first sign of evidence by which the operating
crew will recognize the failure has occurred
ill i h f il h d

– All of the secondary effects that resulted from the
failure

– Events required to bring the process back to
normal operating condition


RCMBlitzTM

Example Failure Effect Statement
Failure Mode – Fuel pump bearing seized due
to lack of lubrication

Failure Effect Statement –

Without proper lubrication, the pump bearing will heat up, vibrate
and if left to its own devices eventually seize (
y (events leading up
g p
to the failure) When the bearing fails the pump shuts down, the
flow switch will alarm the operators when the flow falls below
75 gpm for more than one minute (operators first sign of
evidence)The operator will attempt to restart the pump and it
will again shut down Operator will call maintenance to trouble
shoot, repair and replace (events required to bring process to
normal operating condition)


RCMBlitzTM

The RCM Decision Process
Uses a series of questions to determine:
– The consequence category of the failure
q g y
– A maintenance task to predict the failure
– A maintenance task to prevent the failure
– A redesign task to eliminate the failure
– A failure finding task to reduce the probability of
hidden failures
– An inspection that reduces the probability of
failure to an acceptable level
– A consequence reduction task to reduce MTTR for
run to failure decisions


RCMBlitzTM

Failure Consequences
The first step in the RCM decision process
is to locate the correct category for the
failure consequence
f il

Each Failure Mode will fall into one of these
Fail re ill
four categories:
– Hidden Failure Consequences
– Health, Safety, or Environmental Consequences
– Operational Consequences
– Non-Operational Consequences


RCMBlitzTM

Hidden Failure Consequences
• Consequences that result from the failure of
a Hidden Function

• The failure of this device will not be evident
to the operating crew during the performance
of their normal duties


RCMBlitzTM

Hidden Failures
Examples of components with Hidden
Functions:
– Emergency Stop Switches
– High Level Switches
– Relief Valves
– Rupture Discs
– Pressure S it h
P Switches
– Redundant Devices


RCMBlitzTM

Health, Safety, and Environmental
Consequences

Consequences resulting from a functional
failure that could have a direct adverse effect
on health, safety, or environment


RCMBlitzTM

Operational Consequences
The economic consequences of a failure that
interferes with the planned use of operating
g
equipment

Examples of Operational Consequences:
• Cost of lost production
• Cost f
C t of maintenance
i t
• Cost of replacement parts
• Cost of waste


RCMBlitzTM

Non-Operational Consequences
• The economic consequences of a failure that
does not affect safety or the operational
y
capability of the equipment
• Typically these are non-significant items that
have no hidden functions


RCMBlitzTM

The RCM Decision Process
• Once the correct consequence category has
been selected, RCM then asks a series of
questions to identify the correct maintenance
task


RCMBlitzTM

Spare Parts
• No maintenance strategy is complete without
assessing spare parts
g
– Having the correct spares in place is critical in
reducing failure consequences
• We use a risk based flow diagram to make
spare parts decisions


RCMBlitzTM

Section 6 RCM Implementation

RCMBlitzTM

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RCMBlitzTM

RCM Implementation
• Your RCM analysis is not complete until all
tasks have been implemented

• Each Task should be assigned to a specific
g p
person and assigned a due date

• Implementation can be tracked in the
database


RCMBlitzTM

RCM Management Review Meetings

• Communication is critical to successful
implementation

• Report implementation progress

• Develop future path for critical assets

• C
Communicate success
i t


RCMBlitzTM

Barriers to Successful Implementation
• Failure to prioritize tasks

• Unrealistic due dates

• Analysis/Task ownership

• Resource allocation


RCMBlitzTM

Questions?
rsmith@gpallied.com
ith@ lli d


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