Text

Reliability Centered Maintenance

FAG

BREAKDOWN / FAILURE
RATE of EQUIPMENT
Breakdown: a failure of one
equipment to do its function
Every equipment in every industry
typically follow a so-called bathtub or wear-out curve
A good maintenance program will
extend the minimum breakdown
period
How to create a good
maintenance program?

In RCM we trust!
The purpose of RCM:
Identify the techniques/methods/policies that preserve the function of an asset in its operating (not
design) context
Preserve the function, not just maintain the equipment
With RCM, these items are ensured:
The right maintenance is performed (TASK),
at the right time (INTERVAL/PERIOD),
by the right people (CRAFT),
in the right way (CONDITION, PERMIT, etc),
and with the right training, skills, tools, and spare parts
RCM means less corrective maintenance, more proactive approach

How to get RCM right?

To get the 5 items right, there are 7 questions that need to be asked to each equipment:
What are the desired standards of performance of the assets/equipment in the
present operating context? [FUNCTION]
In what ways can it fail to fulfil its functions [FUNCTIONAL FAILURES]
What causes each functional failures? [FAILURE MODES]
What is the effect of the failures? [FAILURE EFFECT]
In what way does each failures matter? [FAILURE CONSEQUENCES]
What should be done to predict or prevent each failure? [PROACTIVE TASKS and
TASKS INTERVAL]
What should be done if a suitable proactive task can not be found? [DEFAULT
ACTIONS]

Maintenance Activity and its

Cost

At this stage a
valuable RCFA &
FMEA information
could be gathered

Maintenance Activity in RCM

and Current Condition
RCM
Reactive

Preventive

Small items
Non-critical
Inconsequential
Unlikely to fail
Multiple
Redundancy

1.

Our maintenance system

accommodate for these activity. Still
needs a lot of improvement in Job
Plan, reporting, and reviewing
Operator Technician Look-Listen-Feel
able to identify initial stage of failure

2.
3.

Subject to
wear-out
Consumable
Replacement
Failure pattern
known

2.

1.

1.
2.

1.
2.
3.

Proactive

Random failure
pattern
Not subject to
wear
Induced failures

1.
2.
3.

RCFA
FMECA
Age extending
program

}
}

1.
2.
3.
4.
5.

Predictive

Some of our CM came from PdM

follow up
But PdM is not yet implemented
properly. Tools, point of
measurement, results & trending
should be easily accessible by CBM
Engineer

1.
2.

There are improvement

to increase reliability.
Improvement
(engineering or maint.
program) by RCFA and
FMECA are not yet a
culture

How to get RCM right? contd

Planning & Preparation
Identify Teams &
Resposibilities
Identify Assets or Equipments
Prioritizing Items

Analysis
Initial Data Gathering
Equipment Partition
Functions
Functional Failure
Failure Modes

Identify and Document

Review

Failure Effects

Set Ground Rules &

Assumption

Job Plan Evaluation

Failure Consequences

Job Plan Selection

FMECA
needs multi
-discipline
experts

How to get RCM right? contd

Implement Results
Job Plan gap identified
Package Maintenance Job Plan input
Incorporate PdM activity & reporting to Maintenance System
Implement other important actions
Sustain
Reliability & Maintainability Data Analysis
Age Extension Program
Hardware/Equipment Changes
Trending of Degradation
Document Review

Is This The End of a Tunnel?

In the Sustained
Maintenance
Planning scheme,
RCM process only
occupied a small
(but important)
amount of area

Only a Step to Reach

Reliability EAM Organization
RCM Process increase
our maturity in this area: