distribution a. approved for public release: distribution unlimited. 11 usmc reliability centered...

DISTRIBUTION A. Approved for public release: distribution unlimited. 11

USMC Reliability Centered

MaintenanceVersion 1 / Feb 25, 2015

Mr. Del BennieMarine Corps Systems CommandAcquisition Logistics and Product Support (ALPS)Research and Readiness Analysis Team


Agenda

• USMC Policy / MCSC draft RCM Order • MCSC RCM Proposed Integration• MCSC RCM Analysis Process/Execution• Recent and Pending RCM analyses• Notable Analysis Recommendations• DST/RCM/M&S Integration • Ongoing Challenges• Recap• Question and Answer period


USMC RCM Policy

• MCO 4790.25 Ground Equipment Maintenance Program– Promulgated 12 Jan 2014– Officially task MCSC to conduct RCM

Per MCO 4790.25 (GEMP) Commander, Marine Corps Systems Command (MARCORSYSCOM)/Program Executive Office (PEO) As the Marine Corps ground equipment asset (Class VII PEI) life cycle manager, develop, implement, document, assess, and refine program/product management strategies and maintenance support plans throughout materiel life cycle through RCM analysis to support CBM+ concepts and the performance of maintenance within a TPM strategy.

• MCSC draft interim RCM Order– Currently being routed to the various competencies prior to presentation to the

Commander and Program Executive Officer Land Systems for concurrence and signature

– The order is planned to be subsumed by the MCSC Maintenance Planning and Management policy


IOCBA

TechnologyMaturation & Risk

Reduction

Engineering & Manufacturing Development

Production & Deployment

Systems Acquisition

Operations & Support

C

Sustainment

FRPDecisionReview

FOC

LRIP/IOT&ECDR

Pre-Systems Acquisition

MaterielSolutionAnalysis

ConceptDecision

PDR

Proposed Integration (draft)

(DOD 5000)

RCM Analysis

(Proposed)

RCM Analysis/Update

(every 3 - 5 years)

(Proposed)

RCM Analysis/Update*

* other potential trigger events

(Proposed)

RCM/Functional Analysis

(Proposed)

RCM Analysis/Update

(or as required)

1 2 3 4 5 6 6 6 6 6PoPSGates

Draft Process



IOCBA

TMRR E&MD Prod & Depl O&S

C

FRPDR

FOC

CDR

MSA

PDR

Early Functional Analysis

• Chaired by Requirements Developer, supported by MCSC• Defines System Functions and Functional Failures (performance parameters)• Refines common understanding of operating context• Supports AoA activities and Alternate System Review (ASR)• Supports refinement of ICD, Draft CDD and follow on RFPs

5



IOCBA


C

FRPDR

FOC

CDR

MSA

PDR

Pre MS B RCM Analysis

• Chaired by MCSC (as are the remainder of the analyses)• Initial FMECA, MTL/PMCS and system training developed (cursory knowledge of CIs)• Best opportunity to recommend design changes that will enhance reliability prior to establishment of allocated baseline• Supports refinement of Draft CDD, including Sustainment KPP and Reliability and Ownership Cost KSAs as well as follow on RFPs

6



IOCBA


C

FRPDR

FOC

CDR

MSA

PDR

Pre CDR RCM Analysis/Update

• Refined FMECA, MTL and system training based on proposed configuration baseline (matured knowledge of CIs)• Refined PMCS schedule and training to support Product Support Demos and additional DT/OT/FUE/OA events• Supports refinement of CPD (Sustainment KPP, Reliability and Ownership Cost KSAs) as well as follow on RFPs• Out of all of the pre-fielding analyses, this is the most critical due to the fidelity of system design information.

7



IOCBA


C

FRPDR

FOC

CDR

MSA

PDR

Post MS-C RCM Analysis/Update

• Considers results of product support demonstrations and Operational Tests/Field User Evaluations/Operator Assessments• Final refinement to overarching product support strategy, MTL, PMCS schedule, TMs, system training and related products prior to full rate production and fielding.

8



IOCBA


C

FRPDR

FOC

CDR

MSA

PDR

Iterative RCM Analyses/Updates

• Every 3 – 5 years, or trigger event • Captures updated configurations/ECPs• Addresses observed failure trends• Updates MTL/PMCS schedule as more system performance and reliability information becomes available• Provides feedback loop to the Warfighter and to theRequirements developers for similar/replacement systems

9


MCSC RCM Analyses Process

Research & Readiness Analysis

ALPS & Program

Office

Program Office

LEGEND

MCSC RCM ProcessV5.0 09/26/14Analysis

Requested

1Requirement

Validated

2Establish

Objectives & Boundary

3Failure Mode

Estimate

4 5Analysis

Approved

RCM Review Group

Requirements/ Responsibilities

6

A

A

Yes

No

Technical Documentation

8Release of

Naval Message

7Development of Operating

Context

10

Documentation Review

9

Review Group Read Ahead

11

Confirmation brief

12

B

II- Analysis RequirementsI- Analysis Determination

III- Analysis Planning

Orientation/ Group Training

13

BPhase 1:

Information Phase

14

Consensus on Decisions

16

Yes

No

C C

DPhase 2: Decision

Phase

15

IV- RCM Analysis

Provide ILA Documentation

D Technical Audit

18

Technically Correct

19

No

C

Min. 60 Days prior to IV

Publish Updated Analysis

21

22

Recommendations Approved

Yes

Yes

No

Implement Recommendations

23

Record Disapproval

Rationale

25A Living Program

Analysis Complete

17

RCMA

V- Audit Phase

Assignment to Logistics (PMCS, Tech

manual, Training, process), Engineer

(Design) IPT

24

SUSTAIN- Emergent Issues- Age Exploration- Hardware Changes - Trend/degrader analysis- Document Reviews

E

E

VI- Implementation Phase

Management Audit

20

Provide Feedback to R2A

26

180-240 Days


Marine MaintainerMarine

Operator

EngineerProgram Office

rep(s)

SMEs as requiredHFE

SafetyEnvironmentalThermal Engr

Etc.

Task Organized

RCM ReviewGroup

Trained RCM Facilitator

RCM Analyses Task Organized Review Group


Recent/Pending RCM Analyses

Expeditionary Field Kitchen (EFK) Airtronic Burner Multi-Band Radio II FoS (MBR II) Blue Force Tracker FoS (BFT) MK970 Refueler Assault Amphibious Vehicle (AAV) Subsystems:

– AAV P7A1 Hull PMCS– AAV Family Of Vehicles Deadline Criteria– Water Propulsion & Steering Systems– AAV Hydraulic System– AAV Upgunned Weapon Station PMCS– AAV Transmission/Suspension Analysis– AAV Engine/ Fuel Systems– AAV Upgunned WS– AAV Hull electrical/ AFSSS

Logistics Vehicle System Replacement (LVSR) – Steering/Suspension– Engine/Fuel/Air/Exhaust/Cooling– Drive Train/Transmission/Axle/Transfer– Hydraulics Fans/LHS, Winch– Air and Electrical System, CTIS, Backfit, and

Storage Medium Tactical Vehicle Replacement (MTVR)

MK 154 Mine Clearance Launcher AN/TPS-80 Ground/Air Task Oriented Radar M9 Armored Combat Earthmover

RECENT PENDING

http://data3.primeportal.net/apc/chiou_cheng_wen/aav7/images/aav7_5_of_5.jpg

http://www.google.com/imgres?imgurl=http://rf.harris.com/media/117G_enlar_26-12136_tcm26-14105.jpg&imgrefurl=http://rf.harris.com/capabilities/tactical-radios-networking/an-prc-117g/an-prc-117g-wideband-networking-in-action.asp&h=312&w=600&sz=58&tbnid=fz5Va5emuucGFM:&tbnh=58&tbnw=111&prev=/search?q=PRC-117G&tbm=isch&tbo=u&zoom=1&q=PRC-117G&usg=__BM1xMi3YO-D2XSetW65wC-r0sQE=&hl=en&sa=X&ei=-RklUNmjF5Ci8gSe2oGADg&ved=0CDAQ9QEwBg


Program Analysis Recommendations

Assault Amphibious Vehicle (AAV) PMCS

Recommended the reduction of 70% of the PMCS tasks on the AAV platform

Assault Amphibious Vehicle (AAV) Deadline Criteria

Recommended that operational checklists include new columns for deadline criteria and exceptions to non-use

Multi-Band Radio II (MBR II)Recommended development of a mitigation strategy for HUB battery removal (bricking)

Airtronic BurnerRecommended the transition to full organic support at significant cost savings to the USMC

Expeditionary Field Kitchen (EFK)Recommended the reevaluation of the upper temperature operating limit contained in MIL STD 810G (120 degrees F)

Blue Force Tracker (BFT)

Recommendation to investigate a possible redesign to incorporate a software change. If this software change and other recommendations were to be incorporated, the projected 10-year cost decrease to the BFT FoS would reflect a decrease of $464,773 in material costs and a net decrease of 4,863,072 maintenance man-hours at all maintenance levels.

Notable Analysis Recommendations


RCM

SOEDST

M&S

• Predictive Modeling & Simulation applies advanced simulation technology to identify significant return on investment and to resolve asset management challenges.

Pending Initiative• ALPS intends to provide Program Managers within MCSC and PEO LS with synergized RCM, failure analysis and predictive modeling and simulation (M&S) capabilities. This will enable Product Support decisions that maximize readiness and minimize cost.

RCM / SOE DST / M&S Integration


RCM

SOEDST

M&S

• RCM defines what must be done to a system to achieve the desired levels of safety, reliability, environmental soundness, and operational readiness, at best cost (DODI 4151.22). MCSC is currently conducting Reliability Centered Analyses utilizing a stand alone RCM approach however, efforts are underway to integrate the following analysis tools to further realize the benefits and power of RCM:

• Systems Operational Effectiveness Decision Support Tool (SOE DST) The SOE DST is a web based application which utilizes

USMC data stored in the MDR in order to provide reliability and lifecycle trend analysis

• What has happened / is happening

• M&S / DEMAND Pro Is a high-resolution modeling and simulation tool that enables detailed

lifecycle predictions and quantifies risk & uncertainty• What should/can happen

Integration & Opportunities: Analysis Tools


AAV RCM / Modeling & Simulation Integration

- AAV FoV Analysis completed in February 2014- AAV PMCS Modeling & Simulation Analysis September 2013

- Objectives:• Evaluate the current impact of the RCM derived PMCS

recommendations• Evaluate reliability changes due to RCM implementation• Construct and evaluate a high-resolution simulation to assess the

long-term impact of RCM derived PMCS modifications.• Recommend possible modifications to RCM derived PMCS

recommendations

- MetricsPerformance of each alternative is evaluated with five primary metrics

- Cost- Corrective Maintenance - Operational Availability (AO) - Mean Down Time (MDT)- Materiel Availability (AM)

RCM

SOEDST

M&S


RCM Five Year Comparison

17

Pre Post DAchieved Availability 64.5% 71.0% +6.4%Materiel Availability 95.6% 96.9% +1.4%Achieved Hours 531 k 539 k +1.4% (7,500 hrs)PMCS Man Hours 65.4 k 20.3 k –69%Corrective Man Hours 1.64 M 1.67 M +2.0%Parts Cost $76.5 M $77.5 M +1.3%Mean Down Time 38.3 Days 26.2 Days –32%

Pre-RCM• 11 checklists• 64:03:12 hours total if each

checklist performed once• Many redundant tasks • Limited compliance

– “Rainbow” Sheets: daily check of 68 tasks broken into groups, performed over 4-week period

Post-RCM• 15 checklists• 19:37:53 hours total if each

checklist performed once• Greatly reduced redundancy• Greater compliance• Eliminate unnecessary tasks• Deadline criteria clearly defined


• Ongoing Challenges– Non-compliant RCM deliverables (SAE JA1011) – Implementation of recommendations by PMOs– Low demand signal– Misunderstanding of what RCM achieves– Accurate Failure Mode data– SME support


What's wrong?

A design FMEA/FMECA is not synonymous with an RCM FMEA/FMECA

ITEMFUNCTION

FAILURE MODE

CAUSE OPFAILURE EFFECT

TITLE MODE LOCAL NEXT HIGHER END EFFECTS DED 180 DED 128 DED 124 DED 247 DED 126 DED 127 DED 125

001 : Rod End To provide a pivot point for the Balancer. To provide a fixing point for the Rod (item 102).

Structural failure Fatigue Firing/ Emplacement/ Displacement

Rod becomes detached. Piston forced against Cylinder Eye.

Loss of Balancer structural integrity. Cradle may become distorted. Minor instability results in potential minor injury.

Unable to elevate or depress cannon. Stop firing.

002 : Gland To provide a housing for the seals and wear rings (items 204, 205, 206, 207 & 208). To cap the end of the Cylinder (item 101).

Structural failure Fatigue Firing/ Emplacement/ Displacement

Leakage of N2 to atmosphere. No pressure in the system.

No pressure to counterbalance the elevating mass.

Unable to elevate or depress cannon. Stop firing.

The identified function's are the functions of the piece parts and not that of the assetunder review required by RCM

The remaining analysis information is based on preventing the loss of function of the piece parts instead of the asset under review. This leads to a maintenance strategy that does not support the tenets of RCM and therefore cannot be labeled RCM

This is an excerpt of one of many contract RCM deliverables tech audited by AC ALPS RCM personnel. This has been a common theme throughout.


Recap

• USMC Policy/MCSC Draft RCM Order • MCSC RCM Proposed Integration• MCSC RCM Analysis Process/Execution• Recent and Pending RCM Analyses• Notable Analysis Recommendations• DST/RCM/M&S Integration • Ongoing Challenges• Question and Answer Period


Maj. Dustin Thorn703-432-4022

Mr. Del Bennie703-432-3525

Captain Chris Radel703-432-3524

Mr. Herbie Morris703-432-4050

Any Questions?


Backup Slides

Backup Slides


• RCM ISO Depot Maintenance– Briefed Commander MARCORLOGCOM


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distribution a. approved for public release: distribution unlimited. 11 usmc reliability centered...

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rcm analysis update

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rcmfunctional analysis

mcsc draft interim rcm

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usmc rcm policy mco

mcsc maintenance planning