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SEA 04M1

2000 DoD Maintenance Symposium and Exhibition

Applying RCM Principles Applying RCM Principles in the Selection of in the Selection of

CBM-Enabling CBM-Enabling TechnologiesTechnologies

Applying RCM Principles Applying RCM Principles in the Selection of in the Selection of

CBM-Enabling CBM-Enabling TechnologiesTechnologies

Kenneth S. Jacobs (SEA 04M1)Director, Maintenance Engineering

Naval Sea Systems Command

31 October 2000Charleston, SC

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SEA 04M1

CBM – Enabler and Risk ReducerCBM – Enabler and Risk ReducerCBM – Enabler and Risk ReducerCBM – Enabler and Risk Reducer

• Reduced LCC• Decreased Maintenance• Reduced Manning• 3 Year Deployments• New Logistics Paradigm

• CNO maintenance policy• SURFMER• AEC• MRS• Maintenance Education

• Wireless, distributed Networks• “Smart”, self-powered Sensors• Materials / Coatings• Embedded Training

Policy, Processes&

Procedure

Policy, Processes&

Procedure

EnablingTechnologies

EnablingTechnologies

ACHIEVED WITHBALANCED APPROACH

ACHIEVED WITHBALANCED APPROACH

Surface WarfareVision

Surface WarfareVision

CBM

CBM Transition

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SEA 04M1

CBM is a Maintenance Philosophy

CBM is a Maintenance Philosophy

RCM Provides Rules of Evidence

RCM Provides Rules of Evidence

RCM Is the Hub of CBM

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Proof of RCM Success:

The process Uses a review based on RCM principles Examines planned, preventive maintenance (PMS) Performed by In-Service Engineers (ISEs)

SEA 04M1 provides training and post-training support

Progress to date SURFMERs 0 - 31 complete Four-year effort coast-to-coast, starting with Smart Ship

Documented SURFMER savings Exceeded CNO goal of 30% reduction of maintenance

manhours

Achieved 40% reduction by Oct 2000Achieved 40% reduction by Oct 2000

Road Map for applying CBM to Maintenance TasksRoad Map for applying CBM to Maintenance Tasks

Step 4:

Apply Rules for Applicability

TD: Life Renewal Replace/Restore)

CD: Health Monitoring

FF: Hidden Failure (Find/Repair)

S/L: Servicing and Lubrication

Is the Existing Maintenance Task

Applicable?

Task Does Satisfy

Applicability Rules

Task Does Not Satisfy

Applicability Rules

No Yes

• Redesign • Improve task• “Fix when failed”

Determine/Classify Type TaskTIME- CONDITION- FAILURE- SERVICING LUBEDIR. DIR. FINDING (S)

(L)

(TD) (CD) (FF)

Step 3:

APPLICABILITYAPPLICABILITY(Second Filter)

Restores or Maintains

Original Reliability

Step 6:

Improvement Option Goals

• Develop Recommendations for Change

Continuous Improvement: periodic re-evaluation and adjustment of tasks

Step 5:

EFFECTIVENESSEFFECTIVENESS(Third Filter)

Task Is Worth Doing

Is the MaintenanceTask Effective?

Apply Rules for Effectiveness

Safety or the Environment (Law)Operational performance (Mission)All other failures

Task Does Satisfy Effectiveness

Rules

Schedule Task

Task Does Not Satisfy Effectiveness Rules

No Yes

•Extend periodicity•Sample Vs 100% inspection•Make situational•Redesign task•See other options

Identify Failure Mode(E.g., seized bearings)

Step 1:

AGE DEGRADATIONAGE DEGRADATION(First Filter)

Verify Requirement Exists

No Yes

Step 2:Does a Significant

Rate of Age Degradation Exist?

No orAcceptably Slow Rate

of Degradation

Significant Rateof Degradation

•No task

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SEA 04M1

Choosing CBM Technology

Can’t afford it all

Wouldn’t all be worthwhile, anyway

How to choose?

RCM is the key

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RCM Criteria for CBM-Enabling Technology

Failures Happen: Dominant Failure Modes Failure mode is reasonably likely to occur

Applicability Monitored parameter really correlates to the failure mode;

and Measures the parameter consistently and accurately; and Measurements serve as an accurate indicator of required

repair action; and There is adequate time for corrective action before

functional failure.

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RCM Criteria for CBM-Enabling Technology (cont.)

Effectiveness

Safety: Identifies repair threshold in time to reduce probability of failure to acceptable level; or

Mission: Identifies repair threshold in time to reduce risk of failure (probability times severity) to acceptable level; or

Economics: Identifies repair threshold in time to reduce cost to identify and prevent failure at less cost than repairing after run to failure.

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Other Considerations

CBM does not eliminate the need for maintenance Deterioration may occur no matter what the

maintenance approach Goal is to maintain or restore reliability at least cost May allow operator to secure an equipment before

occurrence of disruptive and more costly failure

Costs considered in determination of effectiveness Hardware and software acquisition Development of operating procedures and parametric

values vs. deterioration for monitored equipment ILS costs, including training

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Conclusions

Application of CBM technology can be

crucial to a successful CBM transition

But only worthwhile technology should be applied

A CBM-enabling technology may be worthwhile only if: There is a specific failure mode that is reasonably likely to occur The technology produces applicable results related to that failure

mode The technology allows operators and maintainers to take

appropriate action that reduces probability of failure (safety), risk of failure (mission), or cost of prevention to acceptable levels

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SEA 04M1

SURFMER 2Steam BoilersMK-86 GFCS

SLQ-32CIWS

SURFMER 3Boat Handling/Stowage

Flash Type Distilling Exterior Communications

MK-23 TAS

SURFMER 4Aux Boilers, Waste Heat Systems,

Anchor Handling & Stowage, SQQ-89, AFFF, Sonar Dome

Press, Flex Hoses

SURFMER 5Aviation Fuels, HPAC/LPACs,

Potable Water, Weapons Elevators,

Radar Systems

SURFMER 6Mooring & Towing,Propulsion Diesels,

L.O. Systems, Search Radar Systems

SURFMER 7UNREP, Steering,

Diesel Generators,F.O. Systems,Small Boats

SURFMER 8LP/HP Air Dehydrators, DFTs, Bow Thrusters/

Fin Stabilizers, Desalinization Plants,

SLQ-25, RAST

SURFMER 9Bleed Air, Cranes,

Fire Main, Ventilation

SURFMER Systems to Date

SURFMER 10Main Feed & Condensate

Reduction GearsAC & R

SURFMER 11Tanks & Voids, Motor Controllers,

Navigation Aids, Power Conversion,Main Propulsion GT, Cargo Handling,

Doors & Hatches, Laundry,Propulsion Control

SURFMER 12Electronic Cooling Water, Sewage &

Small Arms, WW Pollution, Oil Pollution, Galley, Laundry, Shop Equip,

Solid Waste

SURFMER 13Aviation Support Facility, Damage

Control, Drainage & Ballasting, Ladder & Access, Lifesaving Equip, De-watering

Gear, Valves, SSGTG, Unrep, Sprinklers

SURFMER 14Aegis, AN/SWY, Electronic Cooling,

Harpoon, Power Conversion, Replenishment, Switchboards, Sea Sparrow, Tomahawk,

Vertical Launching SystemSURFMER 15

Small Arms, 5”/54, 25mm Machine Gun, Aegis, 2M, CIWS, PVPCS, Video MixerSURFMER 16Aegis, Magnetic Tape, Mine-hunting, Mk 46

Torpedo, Navigation, NAVMAC, PortableTest Equipment, Underwater Fire Control,

WSC COMMSURFMER 17Arresting Gear, C-13 Catapults, ILARTS,

Flight Deck Lighting, Cargo Systems,Visual Landing AidsSURFMER 18

AN/USQ, Inflatable Life Boats, NAVMAC,Damage Control, Exterior Communications,

Magnetic Tape Systems, Navigation,Transmitting Systems, WSC-3

SURFMER 19Fire Extinguishing, Salvage Support,

Sprinklers, Damage Control,VentilationSURFMER 20

Torpedo Tubes, Underwater FireControl, Navigation,

Mine HuntingSURFMER 21

CV Specific Systems, Shore Power,400 HZ, TLI’s, Gas Detection, ShaftTorsionmeter Systems, Weapons

Handling GearSURFMER 22

Oil Coolers, Force Draft Blowers,Countermeasure Washdown, Stern Gate,

Air Ejectors, SSTG’s, Mill MachinesO2/N2 Plants

SURFMER 23Reduction Gears, Propellers,

AN/SPN-46, Reboilers, Small Boats,MOGAS, Diving and Salvage, Medical,

Winches, Air Compressors

SURFMER 24Communication, Combat Systems,

Missile Systems, Navigation, UnderwayReplenishment

SURFMER 25Propulsion Boilers, Galley & LaundryEquip, Diver Equip, Damage Control,Pollution Control, Fresh Water Sys

SURFMER 26Weapons Elevators, EOD Equipment,

Anchor Handling & Stowage,LCAC Systems, Calibration

SURFMER 27Boat Handling, Distilling Plants,

Feed & Condensate, Mooring & TowingLife Saving, Shop Equipment, Sonar

Dome, Waste Heat Boilers

SURFMER 28AEGIS, BFTT,

PCMS, MK-86, MK-92, Q-70, CEC, Tomahawk,

VLS, OCSOT

SURFMER 29SLQ-32, 2M, WQC-2/6, UQN-1/4,Stinger, SLA-10, Electro-optical,

SSQ-82, MK 64, USM-465

SURFMER 30Combustion Air, Deaerating Feed Tanks, Fuel Oil, Lube Oil, Shafting,

ICAS, Uptakes and Baffles

SURFMER 31CCTV, Communications, DC WIFCOM, RADIACs,

Security Systems, SQQ-108

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The Context of the Problem

Legacy fleet: Is sizable Will be with us for some time Must be supported

0

10

20

30

40

50

60

FY00 FY05 FY10 FY15 FY20

New ships & legacy fleet must be totally:

Interoperable Compatible Supportable

Fiscal Year

Surf

ace

Com

bata

nt M

anni

ng [1

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]

FFG DD

DDG CG

DD-21

CG-21

LPD-17 LPD-17 LHD LHD

LHA LHA LSD LSD LPD-4 / LSD / LST LPD-4 / LSD / LST

MCM/MHC MCM/MHC

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* OPNAV N86