reliability centered maintenance, rcmsep 04, 2019 · reliability centered maintenance - rcm •...
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Reliability Centered Maintenance, RCM
Steve WilliamsonNovember 19, 2009 / WMEA, San Antonio, Texas
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Reliability Centered Maintenance - RCM
• What is RCM?
RCM is a process used to determine the maintenance requirements of any piece of machinery when it is operating. “Reliability-Centered Maintenance” develops Planned Maintenance Programs which are cost effective processes design to obtain the life expectancy of the component.
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How Does RCM Work?
• Once the RCM process has been applied to a system, assembly, or subassembly the following information is determined:
– Function…What does this component do?– Functional Failure…How can it fail?– Failure Mode…How do you know it had failed?– Failure Effect…What is the impact of the failure?
• The above process is essentially a Failure Mode and Effect Analysis (FMEA).
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Six Failure Patterns
• A – Bathtub curve, infant mortality settling down to a random failure then wear out zone
• B – Traditional view, random failure then wear out zone
• C – Steady Increase in the probability of failure
• D – Sharp Increase in the probability of failure settling down to random failure
• E – Random failure, no relationship to age
• F – Reversed J-curve, infant mortality
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How Does RCM Work?
• Based on the Failure Mode & Effect Analysis, (FMEA), information the RCM process then examines Failure Consequences.
• Will the failure be immediately evident, Y or N?
• Does the failure impact– Safety– The Environment– Operations
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How Does RCM Work?
• Is a task to detect whether the failure is occurring or about to occur technically feasible and worth doing?
• If ‘No’, then there is No scheduled maintenance.
• If ‘Yes’ identify the type of task; inspection, repair, replacement or condition-based task.
• Then identify an ‘Interval’ for the task, (Frequency Hours)
• Then identify ‘who performs’ the task i.e. mechanic.
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RCM Task Analysis
165
923
55
684
Tasks Hours
Original PM SheetsRCM Plan
The Right TaskAt The Right Time
Using The Right PeopleWith The Right Recommendations
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FMEA Results
Functional Location, Description, Failure Cause / Effect, Tooling, Skill, Time
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Maintenance Task Sheet
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PreVail is a hosted solution Simplifies Implementation Reduces Cost of Ownership Instant Software updates Realize more value User access via any Internet
connection
Enterprise HistorianPreVail Application Server
P&H NETWORK
Data LoggerBuffer Sensor & Alarm Data
Client Mine NETWORK
INTERNET
Client Business NETWORK
F W
PreVail via Internet
RHM PreVail Background
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RCM Failure Mode Analysis
1
2
PreVails Diagnostics and reporting tools were developed to:
PreVails Diagnostics and reporting tools were developed to:
PM
CM / Predictive
Life Extension
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RCM Benefits
• Improved productivity through the reduction in unplanned downtime.
• Higher Availability through reduced maintenance hours
• Receive a proactive maintenance plan focusing on what task need to be preformed for each component
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Results to Date 2009
• Machine lives 17,000 to 83,000 Hours
• Availability 85 %to 91% (based on 24x7)
• Mean Time to Failure 78 to 845 Hours
• Mean Time between Failure 159 to 496 Hours
• Mean Time to Repair 6 to 44 Hours
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