Learning Module 01: Maintenance and Reliability Introduction

➔ Evolution of Maintenance
Before war, simple machines, poor mechanization and low dependence on
downtimes.
Second world war started to have higher mechanization, more complex machines
and a certain degree of machines dependence.
Following WW2, air transport became more and more frequent and accessible.

➔ Reliability Centered Maintenance (RCM)

Systematic methodology used to identify the preventive maintenance - related
tasks necessary for realizing the inherent reliability of equipment at the lowest
cost.
1968: (ATA) prepared a document entitled “Maintenance Evaluation and Program
Development” for Boeing 747
1974: (US Department of Defense commissioned United Airlines to develop
maintenance programs for aircraft which resulted in “Reliability Centered
Maintenance”.

➔ RCM Goals
Efficiency
Safety and Reliability
Improvement
Cost Effective

➔ Principles of RCM
RCM is equipment/system focused
RCM acknowledges three types of maintenance tasks along with run-to-failure
RCM use a logic tree for screening maintenance tasks
RCM acknowledges design limitations
RCM tasks must be applied
RCM is a living system
RCM is driven by safety and economic
RCM is reliability centered
RCM defines unsatisfactory conditions as failure
RCM tasks must be effective
RCM is function oriented

➔ The Minimum Criteria

1. Identify system functions
2. Identify failure modes
3. Identify failure causes
 4. Identify effects of failure
5. Identify consequences of failure
6. Determine preventative tasks
7. Identify alternatives

➔ Basic RCM Process

1. Identify high priority items with respect to maintenance by using methods such as
failure mode, effects, and critical analysis (FMECA) and fault tree analysis (FTA).
2. Gather all necessary failure data
3. Perform fault tree analysis
4. Apply decision logic to failure modes considered critical
5. Group Maintenance Requirements
a. Condition-based Maintenance
i. It is a maintenance strategy that monitors the actual condition of
an asset to decide what maintenance needs to be done. This
includes non-invasive measurements, visual inspection,
performance data and scheduled tests.
ii. Predictive testing or inspection
b. Preventie Primary Maintenance
i. It is a process under which an item must be removed from service
at or before a scheduled specified time.
6. Implement all RCM related decisions
7. Apply sustaining engineering on field experience data

➔ Key RCM Program Elements

Reactive Maintenance
a. Other names used for this type of maintenance are breakdown,
fix-when-fail, repair, and run-to-failure maintenance.
b. Thus, this very assumption precludes the identification of a certain class
of repair parts as being more appropriate than others.
c. A solely reactive maintenance–based program overlooks many
opportunities to influence item and equipment survivability, and there is no
ability to influence when the failures occur because of the absence of
actions to control or prevent them.

Predictive Testing
a. Data comparison: An airline can compare data from multiple maintenance
events of an aircraft's system or component to identify trends or recurring
issues. For example, if the data shows that a particular component fails
frequently, the airline can analyze the root cause and determine whether
a change in the maintenance strategy or replacement of the component is
needed.
 b. Statistical process analysis: An airline can use statistical methods to
analyze the data collected during PTI to identify anomalies, trends, and
areas of improvement. For example, an airline can analyze the data
collected during routine inspections of an engine to determine whether the
maintenance program needs to be adjusted.

c. Correlation of multiple technologies: An airline can use multiple

technologies to monitor and analyze the same system or equipment. For
example, an airline can use oil analysis, vibration analysis, and thermal
imaging to monitor an engine's health, and correlate the results to identify
potential issues.

d. Pattern recognition: An airline can use pattern recognition algorithms to

identify recurring issues or failure modes in the PTI data. For example, an
airline can use machine learning algorithms to analyze the data collected
during PTI and identify patterns that may indicate potential issues.

e. Test against limits and ranges: An airline can compare the PTI data
against established thresholds or limits to identify when maintenance is
needed. For example, an airline can compare the vibration levels of an
engine against the established limits to identify when maintenance is
needed.

f. Trend analysis: An airline can use trend analysis to analyze PTI data over
time to identify potential issues before they become critical. For example,
an airline can analyze the trend of engine performance data over several
flights to identify any deterioration in performance or potential issues that
may require maintenance.

Proactive Maintenance
a. Proactive maintenance is a time-based strategy that involves regularly
scheduled maintenance and inspections, while predictive maintenance is
a data-driven strategy that uses real-time data and advanced analytics to
predict when maintenance is needed.

➔ Characteristics of Proactive Maintenance

a. Use of feedback and communications in ensuring that any changes in design or
procedures are rapidly made accessible to managers and designers
b. Periodic evaluation of the technical matter and performance interval of
maintenance tasks
c. Use of a life-cycle view of maintenance and supporting functions
d. Application of root-cause failure analysis and predictive analysis in maximizing
maintenance effectiveness
e. Assurance to a degree that nothing affecting maintenance occurs in isolation
 f. Adaptation of an ultimate goal of fixing the equipment or item forever
g. Use of a continuous process of improvement
h. Integration of functions that support maintenance into maintenance program
planning
i. Optimization and tailoring of appropriate methods and technologies to each
specific application

Preventive Maintenance
a. Proactive maintenance is a strategy that focuses on identifying and
addressing potential issues before they become major problems,
while preventive maintenance is a strategy that focuses on replacing parts
based on a predetermined schedule to prevent equipment failure.
Proactive maintenance is more data-driven and reactive to the actual
condition of the equipment, while preventive maintenance is more
time-driven and can be less flexible.
b. One major drawback of using these parameters to establish task
periodicities is that failure rate data determines only the mean or average
failure rate. Preventive maintenance can be ineffective or costly when it is
the only type of maintenance practiced or used.

➔ Criteria for Determining the Priority for Repair/Replacing in Reactive Maintenance

Priority 1: A cracked or damaged aircraft structure that poses an immediate
threat to the safety of personnel or equipment. The aircraft must be grounded
until the issue is resolved. A fuel leak that is severe and immediate, posing an
immediate threat to the safety of the aircraft.
Priority 2: A hydraulic system failure that could lead to a loss of control of the
aircraft if not addressed in a timely manner. A landing gear that is stuck in the
extended position, which could prevent the aircraft from landing safely.
Priority 3: An avionics issue that is causing significant disruptions to the aircraft's
systems and could lead to delays or cancellations of flights. An issue with the
cargo door that is preventing loading or unloading of cargo, causing a loss of
productivity.
Priority 4: An engine oil leak that is not immediately severe but could lead to
costly engine damage if not addressed soon. A minor corrosion issue that could
result in liability if not addressed in a timely manner.
Priority 5: A minor issue with the aircraft lighting system that could cause minor
delays or disruptions to operations but does not pose a significant safety threat. A
malfunctioning passenger entertainment system that could cause minor
inconvenience to passengers.
Priority 6: Cosmetic issues such as scratches or minor dents on the aircraft that
do not affect the safety or performance of the aircraft. Minor maintenance tasks
such as replacing a burnt-out light bulb or replacing a worn-out seat cover.
➔ Determining Preventive Maintenance Tasks and Monitoring Periodicities
Although there are many different ways to determine the correct periodicity of
preventive maintenance tasks, all these ways are incorrect without the proper
knowledge of the in-service age-reliability characteristics of the item affected by
the desired task.

➔ Main Objective of Monitoring an Item’s Condition is to Establish a Trend for

Forecasting its Future Condition
The failure anticipation from previous
experiences approach is based on the
reasoning that for some items failure history
and personal experiences can provide an
intuitive feel for when to expect a failure.
The failure-distribution statistics approach is
used to determine the basis for selecting
periodicities and it requires full knowledge
of item failure distribution and probability of failure.
The conservative approach is commonly used in the industrial sector and is
concerned with monitoring the item or equipment biweekly or monthly when good
monitoring approaches and sufficient information are unavailable. Often, this
leads to excessive monitoring.

➔ RCM Program Measures

Numerical indicators are considered to be the most effective because they are
quantitative, precise, objective, and more easily trended than words and they
consist of a benchmark and a descriptor.

a. A benchmark is a numerical expression of a set objective or goal.

b. A descriptor is a word or a group of words that describe the function, the
units, or the process under consideration for measurement.

1. Index 1 (Emergency Percentage)

2. Index 2 (Maintenance Overtime Percentage)
3. Index 3 (Equipment Availability)
4. Index 4 (Percentage of Candidate Equipment Covered by PTI)
5. Index 5 (Percentage of Emergency Work)

➔ RCM Benefits and Causes for RCM Methodology Failures

 ➔ Causes of RCM Methodology Failures
Too much emphasis on failure data
Superfluous or hurried RCM application
Analysis performed at too low a level
Only one person assigned to apply the RCM
RCM applied by only the maintenance department
RCM applied by manufacturers or vendors
Use of computers to drive the process

Learning Module 02: Maintenance and Reliability

➔ Failure: The state or condition of not meeting a desirable or intended objective and may
be viewed as the opposite of success. The impact of failure varies from:
a. Minor inconvenience and costs to personal injury
b. Significant economic loss
c. Environmental impact
d. Deaths