r cm brochure
TRANSCRIPT
7/23/2019 r Cm Brochure
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RCM Process
RCM Plan
Outcomes
★Time or Cycle-Based actions?
★Condition-Based actions?
★Run-to-Failure?
Spare Parts andMaterials
★Where is the best placeto hold inventory?
★What should the inventorylevel be?
Maintenance
Performance Optimization
★How?★
Why?★
Where?
★When?★What?★Who?
Proactive
★When should root failurecause analysis beperformed?
★What is the best feedback loop toimprove the design?
★Do standards need tobe developed?
RELIABILITY-CENTERED MAINTENANCE (RCM)
Is Your Plant Running Safely/Effi ciently?
Is Your Fleet “Fleet” Enough?
Are Your Maintenance Costs Too High?
ROOT CAUSE FAILURE ANALYSIS | RELIABILITY PROGRAM SUPPORT
L I F E C Y C L E C O
S T I N G | H I G H L Y A C C E
L E R A T E D S T R E S S T E S T P L A N N I N G | S T R E S S A N A L Y S I S | D E S I G N
O F E X P E R I M E N T S
F A UL TTREEANAL
Y S I S | REL I ABI L I TYPR
EDI CTI ON | F AI L URE
M ODEEF F E CT S AND C
RI TI CAL I TYANAL Y S I S | AL L O CATI ON
THERMAL ANALYSIS | KNOWLEDGE MANAGEMENT | VENDOR QUALIFICATION
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What is Reliability-Centered Maintenance (RCM)? An analytical method based on Design for Reliability (DFR) and Design for Maintainability (DFM) Best Practices
to match your organization’s preventive maintenance capabilities to the design characteristics of your product or
system.
What Benets does RCM Provide?❯
❯ Identifies maintenance actions that will reduce the probability of catastrophic product/system failure
❯
❯ Identifies cost-effective maintenance actions
❯❯ Promotes an optimal mix of maintenance action types
❯
❯ Applicable to DoD, government, industry and commercial systems, products and processes
Design for Reliability (DFR)
C
Analysis
FMECA(Evident & Hidden Failures)
Failure Mode Informaon:
PoF
AnalysisHALT/HAST
ModeSurrogate
Data
Failure Rate/Life Data:
Field Data
Analysis
Test Data
Analysis
Weibull &
Trend Analysis
Surrogate
Data
Design for Maintainability (DFM)
Accessibility Testability
Human FactorsTimes-to-
Repair
Field Performance
InducedFailures
Number of Maintenance
Personnel
Total Maintenance Hours
Maintenance Work
Orders per Year
RCM Decision Analysis
RCM
Plan/Strategy
RCM Task
RCM Task
RCM Task
Opmized
Total Ownership Cost
Product/System
Requirements
RCM Strategies
Run to Failure Prevenve Predicve Proacve
Random failure paerns
Not subject to wear
Prevenve Maintenance-
induced failures
Root-cause failure
analysis
Age exploraon
Failure modes and
effects analysis
(FMEA)/Failure
modes, effects and
cricality analysis
(FMECA)
Subject to wearout
Consumable
replacement
Failure paern
known
Small items
Non-crical
Inconsequenal
Unlikely to fail
Redundant
Qquanterion.com
PoF = Physics-of-failureHALT = Highly Accelerated Life Test
HAST = Highly Accelerated Stress Test
FMECA = Failure Modes, Effects and Criticality Analysis
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What Criteria is Used to Make RCM Decisions?❯
❯ Failure consequences determine priority (safety- or function-critical)
❯
❯ Selection of each preventive maintenance task is based on inherent failure patterns
❯❯ Scheduled maintenance is based on functional or safety consequences
❯❯ Product/system redesign for safety may be required
❯❯ Maintenance actions should be economically justifiable
Besides Safety Issues, What Other RCM Criteria WouldDrive a Potential Redesign Decision?Decision criteria include:
❯
❯ How critical is the impact of failure?
❯
❯ Is the failed item expendable or not?
❯
❯ How effective is redesign at solving the problem?
❯❯ Can Condition Monitoring help, and is it justifiable?
❯❯ What about design redundancy?
Is the item expendable?Can redesign solve the problem
permanently and cost-effecvely?
NO YES
Redesign
PROACTIVE MAINTENANCE
Is there an effecve PM task that
will minimize funconal failure?Is CM cost and priority jusfied?
Is design redundancy jusfied
by cost and priority ?
YES
YES
YES
YESYES
YES
NO
NO
NO
NO
NO
NO
Will a failure have a direct and adverse effect
on crical system or process funconality?
Is there a Condion Monitoring (CM) technology (e.g., vibraon tesng/sensing,
thermography) that will give sufficient warning (alert/alarm) of impending failure?
Accept risk of failure
RUN TO FAILURE
Install redundant units
PROACTIVE MAINTENANCE
Define PM Task and Schedule
PREVENTIVE MAINTENANCE
Define CM Task and Schedule
PREDICTIVE MAINTENANCE
Yes No
Yes NoYes No
Yes No
Yes No Yes No Yes No
Yes NoSafety Mission All Others
Evident Failures Hidden Failures
Hidden or
infrequent
functions
Class D
Other
regular
functions(economics)
Class C
Operating
capability
(economics)
Class B
Critical
Safety
Class A
Scheduled
maintenance is
desired if it iscost effective in
reducing
corrective
maintenance
Scheduled
maintenance is
desired if it is
effective in
reducingprobability or
operational
consequences to
an acceptable
level
Scheduled maintenance
is required and must be
able to reduce risk to an
acceptable level or item
must be redesigned
unless basic design
constraints require
acceptance of the
identi ed risk
Scheduled
maintenance is
required to
reduce risk of
multiple failures
or unavailability
of function to an
acceptable
level?
Function
Is occurrence of a
failure evident to operating
crew in performance of
normal duties?
1
Does the failure
cause a loss of function or
secondary damage that has
a direct and adverse effect
on operating safety?
Does failure
have a direct and
adverse effect on
operational
capability?
Is there an
effective and applicable
prevention task or combinationof tasks that will prevent
functional failures?
Is a scheduled
failure nding
task available
and justi ed?
Is there
an effective and
applicable preventive
maintenance task or
combination of tasks
that will prevent
functional
failures?
Is there an
effective and applicable
preventive maintenance
task or combination of
tasks that will prevent
functional failures?
Is there an
effective and applicable
preventive maintenance
task or combination of
tasks that will prevent
functional failures?
2
3
7
8
65
4
Describe and
classify work
Describe and
classify task(s)
Submit a
safety related
design change
Describe and
classify task(s)
No task
requiredDescribe and
classify task(s)
No task
required
Describe and
classify task(s)
Submit a safety
related design
change if appropriate
No task required
Submit a safety
related design
change if appropriate
quanterion.com
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What Can Quanterion do to Help?❯
❯ Define product/system R&M requirements
❯
❯ Perform Design for Reliability RCM-related tasks
❯− PoF Analysis
❯− Define HALT/HAST and interpret results
❯− Collect/analyze failure mode distributions
❯− Collect/analyze surrogste data
❯−Perform FMEA/FMECA and root cause analysis
❯❯ Analyze and Assess Maintainability Design Attributes
❯❯ Define and implement an RCM Decision Analysis Plan/Strategy
❯− Significant function selection
❯− RCM task evaluation selection & implementation
❯❯ Collect, analyze and assess RCM performance data
❯− Field and test failures, down to root cause
❯− Weibull & trend analysis
❯− Field maintenance data
❯❯ Optimize RCM performance (feedback loop)
Credentials As examples of our credentials in RMQ (as well as software engineering, cybersecurity, and knowledge management), we
are the day-to-day operator of the DoD’s Center of Excellence in these technologies:
❯
❯ Authors of over 80 publications, papers and presentations and software tools in R&M
❯❯ SMRP-certified engineers for direct RCM support
❯❯ ASQ CRE-Certified consulting engineers and instructors in Reliability training
❯❯ Development of joint government/industry R&M Standards and Handbooks
❯❯ Performed R&M assessments and analyses for numerous DoD, government, industrial and commercial
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❯❯❯ Requirements Analysis
❯❯❯ Metrics and Goal Setting
❯❯❯ System Modeling
❯❯
❯ Analysis of Alternatives
❯❯❯ Allocation
❯❯❯ Benchmarking
❯❯❯ Reliability Gap Analysis
❯❯❯ Reliability Program
Planning
❯❯❯ Reliability/Functional
Block Diagrams
❯❯❯ Reliability Prediction
❯❯
❯ Reliability Growth Modeling❯❯❯ FMEA/FMECA
❯❯❯ Fault Tree Analysis
❯❯❯ Risk and Safety Analysis
❯❯❯ Component and
Materials Selection
❯❯❯ Stress Analysis and Derating
❯❯❯ Vendor Selection
❯❯❯ Life Cycle Costing
❯❯❯ Warranty and Sparing
Analyses
❯❯❯ Design of Experiments
❯❯❯ Reliability Centered
Maintenance
❯❯❯ Reliability Test Plan
Development
❯❯❯ Highly Accelerated Life
Test (HALT) Planning
❯❯❯ Environmental Testing
❯❯❯ Stress Test Planning
❯❯❯ Reliability Demonstration
❯❯❯ Failure Analysis & Corrective
Action System (FRACAS)
❯❯❯ Vendor Reliability
Auditing/Assessment
❯❯❯ Product Qualification
❯❯❯ Highly Accelerated
Stress Screening
❯❯❯ Environmental
Stress Screening
❯❯❯ Vendor Qualification
❯❯❯ Warranty Analysis
❯❯❯ Hazard Rate/Risk Analysis
❯❯❯ Logistics (Depot)
Assessment
❯❯❯ Field Reliability Assessment
❯❯❯ Data Collection/Analysis
❯❯❯ Lifetime Extension
ServicesWe provide professional high-quality services in all aspects of RMQ, offering an independent unbiased perspective. We
are happy to enter into Nondisclosure Agreements and have a variety of easy-to-use contracting arrangements.
http://thecsiac.com
Reliability Information Analysis Center
http://theRIAC.org
RCM-Related Documents
❯❯❯ Maintenance Steering
Group (MSG-3)
❯❯❯ NAVAIR 0D-25-403. “Guidelines for
the Naval Aviation RCM Process”
❯❯
❯ Army Pamphlet 750-40, “Guideto RCM for Fielded Equiptment”
❯❯❯ MIL-STD-3034, “RCM Process”
❯❯❯ Society of Automotive
Engineers (SAE)
❯− SAE JA 1011, “Evaluation
Criteria for RCM
Processes”
❯− SAE JA 1012, “A Guide to
the RCM Standard”