IFS APPLICATIONS

FOR
RELIABILITY
CENTERED
MAINTENANCE
ACHIEVE MAXIMUM OPERATIONAL AVAILABILITY WITH SAFE
BUT MINIMUM LEVELS OF MAINTENANCE
OUR SOLUTIONS DNA
When we first set out to create IFS Applications over 25 years ago, our goal was
to make the most usable business software on the market. And to help us achieve
that ambition, we put simplicity at the forefront of everything we did.
We still do.
We decided that we would make only one product, which can be easily configured
to match the specific requirements of a broad range of industries.
We still do.
We decided that we would build IFS Applications on standards so our customers
would not be locked into any particular technology.
We still do.
We decided to design IFS Applications as a component-based structure so it can be
easily extended and updated.
We still do.
We decided that each software component must be totally compatible with every
other, yet capable of running independently.
We still do.
We decided to build a product that could handle change and long-term evolution.
We still do.
And, that we would make the most user-friendly business software on the market.
We still do that, too.
3 RELIABILITY CENTERED MAINTENANCE
IFS RELIABILITY CENTERED
MAINTENANCE
Reliability Centered Maintenance (RCM) is the 21
st

century, defensible, methodical and scientific
approach to the establishment of safe minimum
levels of maintenance. It also supports changes to
operating procedures and strategies and the establish-
ment of capital maintenance regimes and plans. This
leads to increases in cost effectiveness, equipment
uptime, and a greater understanding of the level of
risk that an organization is presently managing.
WHY RCM?
Historically, the traditional approach to maintenance
planning by service and maintenance engineers
applied the premise that it is better to have a pre-
ventive service and maintenance regime than one
based on only repair when there is a failure.
However, history has proved time and time
again that invasive maintenance can compound the
situation and introduce further failure.
RCM uses a range of approaches, within a
decision framework, to deliver the optimum main-
tenance strategy for complex, safety-critical assets,
balancing risk, cost and environmental factors to
extend through life expectancy.
WHAT MAKES RCM DIFFERENT?
The origins of the RCM approach were based in the
need to manage the increasing equipment complexity
and costs within the aviation industry. The driver
was to improve safety records in the 1960s and 70s,
during the transition between propeller and jet
propulsion technology.
RCM also has its origins in a key study commis-
sioned by the US DOD (carried out by Nowlan and
Heap from United Airlines) in 1978. The Nowlan
and Heap study found that the fundamental assump-
tions made by design and maintenance planners on
the expected life of reliable service from components
such as aero engines, undercarriage, navigation
systems etc. were wrong in almost every specific
example in a complex jet airliner. These findings
created a paradigm shift in the understanding of
failure management, including:
a realization that the vast majority of failures are
not necessarily linked to the age of the asset;
the need to focus on managing the process of
failure rather than trying to predict life expectancy;
a need to understand the differences between
the user requirements of an asset compared with
the design capability;
a need for an understanding of the management
of the condition of an asset;
a strategy to link the levels of tolerable risk to
maintenance strategy development.
These initial findings were further developed by
Moubray in his industry-leading book RCM II,
first published in 1991. Here he characterized RCM
as a process to establish the maintenance require-
ments of a physical asset in its operating context and
an engineering framework that enables the definition
of a complete maintenance regime. Fundamentally,
RCM regards maintenance as the means to maintain
the functions a user may require of equipment in
a defined operating context. It does this by taking a
detailed approach to individual components within
equipment, such as a pump, while also addressing
how the pump fits holistically into the asset in
which it operates, together with the performance
criteria and safety-related issues that have been
established for the asset.
4 RELIABILITY CENTERED MAINTENANCE
Managers with responsibilities for asset performance
principally for reliability and availabilityface a
significant challenge in selecting the most appropriate
technique in the face of several different failure types.
IFS uses RCM to support a structured decision-
support process that consists of the following steps:
define the maintenance problem and gather
basic information;
define the functions and desired performance
standards for each item of equipment;
define all the ways in which it can fail to deliver
the required performance (functional failures);
establish the causes of failure (failure modes);
record what happens when each failure mode
occurs (failure effects);
establish a strategy for dealing with each failure
mode based on an assessment of failure conse-
quences (protection which is not fail-safe,
failures which endanger life or the environment,
failures which affect the organizations business
objectives, failures that only involve the cost of
repair);
assess the applicability of different types of
failure prevention and establish task frequencies
(condition-based maintenance tasks, scheduled
overhaul tasks and scheduled discard tasks).
IFS Applications provides the framework within
a software business solution to help organizations
develop an RCM strategy, and collect the data, for
the management of complex and mission critical
assets.
GETTING STARTED
WITH RCM
TRADITIONAL
BATHTUB
SLOW AGING
BEST NEW
RANDOM
WORST NEW
1940 1950 1960 1970 1980 1990
Reactive Maintenance: fix it when it breaks
Preventative Maintenance: scheduled overhauls and
replacements
Predictive Maintenance: e.g. Condition
Monitoring
Detective Maintenance:
Risk Management
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Acknowledged Failure Patterns
Evolving Maintenance Strategies
5 RELIABILITY CENTERED MAINTENANCE
There are some 450 global customers of the IFS RCM
Toolkit. The footprint includes such diverse industries
as Oil Production, Vineyards and Wine Production,
Defense and the Chemical industry.
RCM should be used in any industry that imple-
ments complex or capital intensive assets or is
reliant on correctly functioning assets to provide an
output.
RCM provides an industry standard to define a
maintenance program, creating a cost-effective
maintenance strategy to address dominant causes
of equipment failure. It ensures that Safety,
Environmental and Operational failures are mini-
mized, while reducing over-maintenance. It results in
a maintenance program that focuses scarce economic
resources on those items that would cause the most
disruption if they were to fail.
RCM can provide you with a systematic approach
to optimizing your asset maintenance. Successful
implementation of RCM will lead to an increase in
cost effectiveness, machine uptime, and a greater
understanding of the level of risk that your organi-
zation is presently managing.
CASE STUDY BENEFITS USING IFS RCM
The UK Royal Navy has implemented IFS and
RCM throughout its fleet. It predicted a consider-
able reduction of maintenance, while still ensuring
that safety and operation are maintained, even in
safety-critical assets such as nuclear submarines.
IFS has supported the delivery of key benefits
through its IFS RCM Toolkits, and the UK Royal
Navy has seen a significant return on investment,
including:
AC power generation & distribution maintenance
reduced some 45%
Steam system maintenance and diesel generator
maintenance reduced by over 60%
HP air system maintenance reduced by more
than 52%
Radar & ESM maintenance reduced by at least
65%
Lubrication oil system maintenance reduced
by nearly 70%
Sonar maintenance reduced by nearly 50%
THE IFS RCM TOOLKITTHE LEADING
INTEGRATED RCM SOLUTION
WHAT RCM CAN DO
FOR YOU
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6 RELIABILITY CENTERED MAINTENANCE
IFS RCM TOOLKIT
IFS RCM Toolkit enables storage of maintenance
strategies derived using RCM analysis techniques in
a database. It is specifically targeted to deliver the
optimum maintenance strategy for complex, safety
critical assets, balancing risk, cost and environmental
factors to extend through life expectancy.
The IFS RCM Toolkit delivers core RCM process
support capability using the latest presentation
technology. It supports the criteria for RCM (SAE
JA1011). Customers also have the option to use the
RCM Toolkit delivered through Software as a Service
(SAAS). Training and consultancy is available using
our strategic partners.
The RCM Toolkit:
Provides an industry standard to define a main-
tenance program
Creates a cost-effective maintenance strategy to
address dominant causes of equipment failure
Ensures Safety, Environmental and Operational
failures are minimized
Helps reduce over-maintenanceacknowledges
that the majority of failures are not age-related
Results in a maintenance program that focuses
scarce economic resources on those items that
would cause the most disruption if they were to
fail.

7 RELIABILITY CENTERED MAINTENANCE
Supports an auditable and defensible
maintenance strategyExercising duty
of care
Reduced through life costsReferenceable
cases reported 20% savings through
correct application of IFS RCM.
Overall maintenance burden is reduced
Personnel stretch eased.
Operational availability is increased.
Greater understanding of equipment by
all involvedwith risks documented to
aid maintenance deferral/deployment
decisions.
Ownership of results
BENEFITS TO YOUR ORGANIZATION
RCM Authoring Tool Authoring of RCM Analyses Fully configurable to meet diverse industrial needs
Workflow
Versioning and approvals
workflow capability
Aids control and rigor of output production to improve
efficiency
FMECA Tool
FMECA (Failure Mode, Effects
and Criticality Analysis)
Intuitive entry for Failure Mode, Effects and Criticality informa-
tion significantly aids ease of use and thus productivity
Failure Management
Strategy
Maintenance tasks and
intervals
Defined schedules aid planning and spares procurement
Standards Supports multiple standards User configurable, e.g. RCM 2, DefStan 00-45, etc.
FFI Calculator
Built-in Failure Finding
Interval Calculator
Aids effective determination of maintenance intervals
RCM Analysis
validation
Auto-validation
Automatic analysis validation based on the user-defined
standard aids QA
Report Generation Standard Reports Proven pre-formatted industry-standard reports
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www.IFSDEFENCE.com
THI S DOCUMENT MAY CONTAI N STATEMENTS OF POSSI BLE FUTURE FUNCTI ONALI TY FOR I FS SOFTWARE PRODUCTS
AND TECHNOLOGY. SUCH STATEMENTS OF FUTURE FUNCTI ONALI TY ARE FOR I NFORMATI ON PURPOSES ONLY AND
SHOULD NOT BE I NTERPRETED AS ANY COMMI TMENT OR REPRESENTATI ON. I FS AND ALL I FS PRODUCT NAMES ARE
TRADEMARKS OF IFS. THE NAMES OF ACTUAL COMPANIES AND PRODUCTS MENTIONED HEREIN MAY BE THE TRADEMARKS
OF THEI R RESPECTI VE OWNERS.
IFS AB2012
IFS is a public company (OMX STO: IFS) founded in 1983 that develops,
supplies, and implements IFS Applications

, a component-based
extended ERP suite built on SOA technology. IFS focuses on agile
businesses where any of four core processes are strategic: service
& asset management, manufacturing, supply chain and projects.
The company has more than 2,000 customers and is present in
50+ countries with 2,700 employees in total.

If you are interested in further information, e-mail info@ifsdefence.com
or contact one of our regional offices or visit our web site:
www.IFSDEFENCE.com
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ABOUT IFS AND IFS APPLICATIONS