RCM - Maintenance

Philosophy of the Future?

by Peter Ormond, Strategic Corp.,
Australia
Reliability Centred Maintenance
Original paper by Nowlan and Heap, 1978
Major re-work in RCM II by John Moubray
SAE Standard JA1011 in 1999
Maintenance Philosophies
Breakdown
Maintenance
Industrial
Revolution
Preventive or
Change-out
Maintenance
Second
World
War
Predictive or
Condition
Based
Maintenance
Mid 60s
Reliability
Centred
Maintenance
Mid 80s
BHPs Experience
Steel Industry World Wide Review
Man-hours per Liquid Tonne of Steel
Four Best Practice Organisations
Biggest difference Maintenance treated as a
PROFIT CENTRE
BHP was managing Maintenance as COST
CENTRE
BHP Action Plan
Understand Problem
Set Overall Target
Target 40% Reduce in Maint. Cost Per Tonne
in 5 years
Develop Approach for Solution
7 Step Plan
BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Education
Develop a new technique for applying
training - SBL
Develop a high level training package
Introduction to Maintenance and its
Management
Apply training package to ALL employees
BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Roles & Responsibilities
New understandings required new
definitions
Some changes to organisational structure
Once-off exercise
BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Measurements
The only way to make permanent change
is to change the way things are measured
Split measurements between KPIs and
the PIs that feed them
KPIs are ALL Historical, Summary and
UNCONTROLLABLE
Measuring is not enough, interpreting the
measures is the important step
BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Processes and Systems
Follow-on from all the previous steps
Includes fully developed processes,
procedures, documentation, etc.
Also includes adequate computer systems,
both hard and software, as well as
appropriate training
BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Strategy Based Maintenance
Understand Profit Centre Maintenance
Travel World looking for solutions
RCM recognised as fitting exactly with
required philosophy
Love results Hate effort required
Develop Methodology to enhance RCM
(RCM Turbo)

BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Continuous Maintenance
Improvement
Appoint responsibility
Formalise process
Recognise shortcomings of P-D-C-A
Change Act to AUTHORISE
BHPs 7 Step Plan
1. Re-Education
2. Re-Define Roles & Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction
Waste Reduction
Very similar to Continuous Maintenance
Improvement
Look outside normal Maintenance sphere
Same structure but less frequent
BHP Steels Results
Achieved 50% reduction in 6 years
Pointed to two factors having greater
impact than anticipated:
Re-Education of all employees into common
understanding of Maintenance
Implementation of RCM (RCM Turbo)
World Wide View
Late 80s
Paper based analyses
Several successful exercises
No PC Tools
Almost no-one had heard of RCM
World Wide View
Mid90s
Many heard of RCM but few knowledgeable
Several Tools
Other systems claiming to be RCM
SAE Standard JA1011

World Wide View
Current 2000+
Few organisation not heard of RCM
Most organisations have some-one with
detailed knowledge
Many organisations have Reliability Group
Many others trying to start projects
RCM Incorporated into University Courses

How does it all fit together?
Business Plan
Plant Strategy
Operating requirements
Inventory plant items
Life Plans for critical plant items
(RCM analysis)


Document Retrieval System
Work instructions
CMMS
Task lists
Maintenance plans
Work orders
RCM-Turbo The Versatile Tool
Equip Codes
Fail Analysis
Task Analysis
Opt Freq
Grp Tasks
Resource Bal
Scheduling
KPI
Review
Reactive Maintenance Systems Maturity Proactive
I
m
p
r
o
v
e
m
e
n
t

S
t
e
p
s

RCM-Turbo The Versatile Tool
Equip Codes
Fail Analysis
Task Analysis
Opt Freq
Grp Tasks
Resource Bal
Scheduling
KPI
Review
CMMS
I
m
p
r
o
v
e
m
e
n
t

S
t
e
p
s

Reactive Maintenance Systems Maturity Proactive
RCM-Turbo The Versatile Tool
Equip Codes
Fail Analysis
Task Analysis
Opt Freq
Grp Tasks
Resource Bal
Scheduling
KPI
Review
RCM
CMMS
I
m
p
r
o
v
e
m
e
n
t

S
t
e
p
s

Reactive Maintenance Systems Maturity Proactive
RCM-Turbo The Versatile Tool
Equip Codes
Fail Analysis
Task Analysis
Opt Freq
Grp Tasks
Resource Bal
Scheduling
KPI
Review
RCM
RCM-Turbo RCM-
Turbo
CMMS
I
m
p
r
o
v
e
m
e
n
t

S
t
e
p
s

Reactive Maintenance Systems Maturity Proactive
Cost of Inspection
Cost of Failure
Total
Annual
Business
Cost of
Maint.
Optimum
Frequency
Time
MTBF
FTM - Optimum Frequency based on Probability of Failure in MTBF
Frequency Optimisation
70% Confidence non-failure
92% Confidence non-failure
Warning Time
P
F
1
F

Warning Time
Cost of Inspection
Cost of Failure
Total
Annual
Business
Cost of
Maint.
Optimum
Frequency
Time
MTBF
CBM - Optimum Frequency based on Confidence of non Failure in Warning Time
Warning Time
Cost of Planned Repair
Frequency Optimisation
Frequency Optimisation Graph
Benefits Obtained from
Frequency Optimisation
Many Tasks Increase in Frequency
Increasing Reliability
Many Tasks Reduce in Frequency
Reduced Costs without Compromising
Reliability
Average Cost Reduction 10% 15%
Assists What If..? Scenario Testing
Justification of Maintenance Decisions
Benefits of RCM
Changing Organisations to Profit Centre
rather than Cost Centre Maintenance
A Methodology to apply Business Decision
to Maintenance Planning
Supports all Current Maintenance
Techniques
Consistent with and sub-part of TPM
Title Question
RCM Maintenance Philosophy of the
Future?
YES !