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Research has revealed that most equipment failures are random in nature and that the traditional concept of age-related failure,with its regime of calendar-based intrusive maintenance, is both wasteful in terms of equipment life and extravagant in terms of maintenance effort.
RCM is a methodology used to determine the maintenance requirements of shipboard equipment to ensurethat it fulfils its intended function within its operating context. It has been widely used in the commercial world, including thecommercial aviation and nuclear power industries, and is recognized as being the key to ensure reliability and cost-effectivemaintenance. The RCM process takes account of how the asset is used and the function it performs to determine a failuremanagement strategy that will ensure that it can continue to achieve its required performance. RCM then determines the mostcost-effective method of maintaining optimum operational availability, taking account of all appropriate safety, environmentaland operational consequences.The maintenance resources in the organization must now be focused on the activities that drive the reliability of the ship:1) Design out the repetitive problems2) Increase the lifetime of the machines3) Condition monitoring during normal operation4) Condition monitoring during planned stops5) Time based overhauls6) Redundancies are designed into the process7) Corrective work The condition-monitoring program becomes necessary, as the pre-warning time of developing machine problems are vital for thestrategy. The maintenance work is carried out during planned stops and all unplanned activities are considered as a problem thathas to be prevented from occurring again. The unnecessary overhauls and breakdowns are eliminated so the labour hours can befreed to work on improving the quality of the machines. Condition monitoring is also used to identify the route-cause of the problem so the right corrections or design changes are made. This strategy becomes a positive spiral that feeds on it-self with,fewer breakdowns, less spare part consumption, better planning of needed man hours, increased safety, better environment andimproved reliability. When a full cultural change has been made only 20% of the work is actually spent on the traditionalmaintenance work. The resources can be allocated to maintain the asset value of a ship and the reliability improved at a lower cost; the profits go up.Reliability-based maintenance involves the use of data on the performance of equipment across a fleet of ships to determinewhether or not a specific component or piece of equipment is performing as required. Using this data, owners and operators canmake informed decisions about how to schedule their maintenance and whether to repair or replace items, resulting in more cost-effective maintenance.
LLYOD’S REGISTER AND RESURGENCE’S WAVESOFTWARE:
Benchmarking, previously the preserve of the manufacturing, commercial aviation and nuclear power industries, has started tomake headway in the shipping industry. One area of ship operations which could benefit substantially from the application of benchmarking is that of shipboard maintenance, especially at a time when ship-owners have to operate in an environment whichmakes it increasingly difficult to strike a balance between quality of operation and cost-efficiency. Currently, most ship operatorsemploy a preventive planned maintenance approach that involves performing maintenance on components or equipmentaccording to a prescribed schedule. However, the industry is now displaying a marked interest in what is known as ‘
’, an approach based on benchmarking principles which helps owners and operators to not only reduce their maintenance costs but to also enhance the safety of their operations.Ship-owners and operators stand to benefit from lower overall maintenance costs and better availability by applying reliability- based maintenance onboard their ships.
There is now a marine-specific software system called
produced by US-basedcompany Resurgence and jointly marketed with Lloyd’s Register which allows users to do this easily and efficiently.
is an effective tool which can help users to realize these benefits.
can be used to generate a number of reports based on 14 equipment performance indicators. These reports include:1. Mean time between failures (MTBF) target assessment, which allows users to determine which pieces of equipment are not performing at the required level2. Chronic failures, which enables users to identify pieces of equipment which consistently fail3. Manufacturer benchmarking, a tool for comparing the reliability of different pieces of equipment to aid better procurementdecisions.The software system also includes a charting module which allows users to identify trends over time and to gaugeongoing performance through the creation of a range of charts, as well as a failure review board module which can help tofacilitate root-cause analysis of failures, enabling the elimination of repetitive failures.