Advanced Reliability Centered Maintenance

Preventive Maintenance (PM) only is not the solution!

Preventive maintenance is so institutionalized in many facilities today that engineers don't even question whether their maintenance practices affect system reliability. Up to 50 percent of unplanned downtime occurs in “ serviced “ systems within the previous 7 days, according to research from the Palo Alto, CA-based Electric Power Research Institute and the U.S. Navy. So, if the preventive maintenance program's goal is to prevent production interruptions, it's time for maintenance engineers to reconsider their approach to maintenance.

Reliability-cantered maintenance is much more than just another way to do maintenance. It's a way of looking at system performance in terms of the impact of a failure and then mitigating those results by design, detection, or effective maintenance.

RCM analysis provides a structured framework for analyzing a physical asset's functions and potential failures, focusing on preserving system functions rather than assets. RCM is used to develop scheduled maintenance plans that will provide an acceptable level of operability, with an acceptable level of risk, in an efficient and cost-effective manner

RCM is one of the most powerful asset management processes that can be employed.

RCM principles are so diverse that they can be applied to any asset - an airplane, nuclear power plant, truck, tank, ship, manufacturing plant, offshore oil platform, mobile air conditioning unit, tow tractor, jet engine, a single pump, or an engine control unit. RCM principles can be widely applied to an entire asset or more narrowly applied to select pieces of equipment.

The RCM Solution by Nancy Regan

A Reliability Centered Maintenance or RCM implementation in an industrial plant aims to increase its availability and reduce maintenance costs.

Course Objectives:

• Know how to describe and implement the RCM process flow  
• Understand the importance of identifying and categorizing the assets  
• A deeper understanding of the theory, processes, and procedures needed to supervise, implement, and perform RCM analysis to select the most cost-effective maintenance strategies and tasks for each asset
• Deliver the higher maintenance performance that the management of any company wants
• Implement the RCM through the CMMS system
• Improve the CMMS failure codes to enable the implementation of the RCM on the go.
• Implement the Key Performance Indicators for maintenance in general and for RCM specifically.
• The required organizational readiness elements to implement the RCM project  
• Manage and implement the RCM project successfully.  
• Provide attendees with an understanding of the RCM methodology defined in the SAE JA1011 standard.
• Train the participants on the new techniques utilized for Reliability Centered Maintenance in the industry. Work will be focused on the difference between RCM and all other maintenance strategies, and the participants will be trained to implement the associated techniques and procedures with RCM philosophies.
• Upon completion of this course, attendees will know to:

Day 1 – Understanding How RCM Evolved from the Main Maintenance Strategies  

• Where is Maintenance in the Big Picture?
• Why do we need to understand Maintenance First?
• Main Maintenance Types and Strategies
• Reactive Maintenance
• Run to Failure Maintenance  
• Corrective Maintenance  
• Preventive Maintenance (PM)
• Philosophy, application, risks, and when it can be effective  
• Condition Based Maintenance (CBM)
• Predictive Maintenance (PdM)

Day 2 – Asset Criticality Assessment as a Key Step for any Maintenance and Reliability Initiative - Understanding Reliability Centered Maintenance (RCM)

• Asset Criticality Assessment/Analysis as the first step for any reliability initiative  
• How to perform Asset Criticality analysis?
• What is Reliability Centered Maintenance (RCM)?
• RCM History
• RCM Published Guidelines and Standards
• RCM Objectives
• RCM Principles
• RCM Integrates Maintenance Strategies
• RCM Benefits
• Operating Context
• RCM Process Overview
• Types of RCM
• RCM Analysis
• Building the Strategy Team
• Assess Current Maintenance Processes
• RCM Analysis sequence
• RCM Procedure

Day-3 Reliability Centered Maintenance (RCM) Implementation Steps  

• Step 1: System Selection and Information Collection
• Step 2: System Boundary Definition
• Step 3: System Description and Functional Block Diagram
• Step 4: System Functions and Functional Failures
• Step 5: Failure Mode and Effects Analysis
• What is Failure Mode and Effects Analysis (FMEA)?
• What is Failure Mode?
• Example of Failure Mode Identification
• Hidden and Evident Failures
• What is Failure Cause?
• Failure Effects
• Failure Consequences
• Example of Step 5: FMEA
• The RCM Decision Process
• Step 6: Logic Tree Analysis (LTA)
• Step 7: Selection of Maintenance Tasks
• Step 8: Task Packaging and Implementation
• Step 9: Making the Program a Living One — Continuous Improvements
• Summary of RCM
• RCM Examples

Day-4 Managing RCM program through the CMMS – KPIs & RCM Metrics – RCM Project Guide

• What’s the difference between FMEA and RCM?
• FMEA as a Standing Alone Analysis (not part of RCM)
• FMEA Process
• Example of FMEA Worksheet
• FMEA Worksheet details
• Calculating the RPN  
• Examples of FMEA
• Example of FMEA from NASA reference  
• Is your CMMS/EAM capable of capturing the RCM analysis requirements?  
• Current failure code hierarchy in most CMMS/EAM systems
• How do you configure your system to capture the RCM analysis requirements on the go?
• Manage used Key Performance Indicators (KPIs)
• What is KPIs?
• Leading & Lagging KPIs, what is the Difference?
• Examples of Key Performance Indicators (KPIs)
• Relevant RCM Key Performance Indicators (KPIs)  
• Project Guide for RCM Implementation
• Section-1: Introduction
• Section-2: An RCM Primer
• Section-3: Deciding to Conduct an RCM Project
• Section-4: Valuable Lessons Learned by Other Organizations
• Section-5: Completing an RCM Study
• Section-6: Implementing the RCM Study
• Section-7: Measuring the Benefits
• Section-8: Sustaining an RCM Program
• Wrap-up and course evaluation