RCM - Module 1 11-13-17 PDF

Reliability-Centered Maintenance –
An Introduction
M o d u l e 1
N o v e m b e r 2 1 - 2 4 , 2 0 1 7
1 Basic Foundation of Reliability Centered

Maintenance
In this Training, Our OBJECTIVES are to:
• Appreciate ‘Operation and Maintenance’ as Vital Stage of
Asset Life Cycle
• Understand the ‘Actual Rationale’ of WHY we need to do
Preventive Maintenance
• Have an objective but strategic view of Failure Management
as key component of Fleet Management
• Use a logical approach in determining the ‘most appropriate’
Maintenance Task Package for the DPWH Fleet

2
Maintenance
Module 1 - Outline
• Overview of Reliability Centered Maintenance
• United States Maintenance and Reliability Case
Study
• Human Error
• Origin of Reliability Centered Maintenance
• Asset Life Cycle Stage: Operations & Maintenance
• Reliability, Availability and Maintainability (RAM)

Maintenance
Overview of Reliability
Centered Maintenance

Maintenance
Reliability Centered Maintenance is…
“METHOD to identify and “A LOGICAL, STRUCTURE

select FAILURE FRAMEWORK for the
MANAGEMENT POLICIES determining the concrete mix of
applicable and effective
to efficiently and effectively maintenance activities needed to
achieve the required safety, sustain the desired level of
availability and economy of OPERATIONAL RELIABILITY of
operation.” systems and equipment while
- Dependability Management ensuring their safe and
Part 3.11: Application Guide—Reliability economical operation and
Centred Maintenance, 2011 support.”
-p.1 Practical Application of Reliability Centered
Maintenance
Reliability Information Analysis Center (RIAC),
2002

Maintenance
Five Basic Elements of an RCM Process
1 2 3 4 5
Implementation Continuous
Initiation Functional Task Improvement
and Failure Selection
Planning Analysis

Maintenance
Reliability Centered Maintenance is…
A process of systematically analyzing an engineered system to
understand:
i. Its functions
ii. The failure modes of its equipment that support these functions
iii. How then to choose an optimal course of maintenance to prevent the
failure modes from occurring or to detect the failure mode before a
failure occurs
iv. How to determine spare holding requirements
v. How to periodically refine and modify existing maintenance over time
- GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE
American Bureau of Shipping
2004

Maintenance
RCM PROCESS OUTPUTS
1. INITIATION & PLANNING
a) Identify RCM Team and Members
b) Determine the boundaries and objectives of the analysis RCM TEAM, PLAN AND
c) Determine the content of the analysis
OPERATING CONTEXT
d) Identify the specialist knowledge and experience available, responsible, the need for outside
expertise and any training requirements
e) Develop operating context of the Asset
2. FUNCTIONAL FAILURE ANALYSIS

a) Collect and analyze any field data and available test data
b) Perform functional partitioning FMEA/FMECA
c) Identify functions, functional failures, failure modes, effects and criticality
3. TASK SELECTION
a) Evaluate failure consequence MAINTENANCE
b) Select the most appropriate and effective failure management strategy TASKS
c) Determine task interval if possible
4. IMPLEMENTATION
a) Identify maintenance task details MAINTENANCE
b) Prioritize and implement other actions
c) Rationalize task intervals PROGRAMME
d) Initial age exploration
5. CONTINUOUS IMPROVEMENT
a) Monitor maintenance effectiveness
b) Monitor against safety, operational and economic targets FIELD DATA
c) Perform age exploration
Maintenance
Five Basic Elements of an RCM Process
RCM TEAM, PLAN
MAINTENANCE
AND OPERATING FIELD DATA
TASKS
CONTEXT
1 2 3 4 5
Implementation Continuous
Initiation Functional Task Improvement
and Failure Selection
Planning Analysis
Failure Mode Effect

Analysis/Failure Mode, MAINTENANCE
Effect and Criticality PROGRAMME
Analysis Basic Foundation of Reliability Centered
9
Maintenance
of RCM
1. System dependability can be 5. Maintenance managers have a
increased by using more management tool which
appropriate maintenance enhances control and
activities; direction;
2. Overall costs can be reduced 6. Maintenance organization
by more efficient planned obtains an improved
maintenance effort; understanding of its objectives
3. A fully documented audit trail and
is produced; 7. Purpose and the reasons for
4. A process to review and revise which it is performing the
the failure management scheduled maintenance tasks.
policies in the future can be
implemented with relatively
minimum effort;

Maintenance
RCM’s
Relationship with
Goal is to..
Failure Consequence..
• Avoid or reduce • Personal and
Failure Equipment Safety
Consequences • Environmental
Health/Compliance
• Not necessarily to • Operations
avoid failures • Economics - Along with
the evidence of failure –
Hidden or Evident

Maintenance
In Short, RCM as a
Methodology Has 4 Unique
Features…
• Preserve functions.
• Identify failure modes that can defeat the
functions.
• Prioritize function need (via failure modes)
• Select applicable and effective PM tasks for
the high priority failure modes.
Maintenance
United States Maintenance and
Reliability Case Study

Maintenance
Global Trend on Maintenance and
Reliability – US Case
Preventive Maintenance Program
Global Satisfaction Survey
• In 1979, MIT estimates showed USD 200 Billion spent on Reliability and
Maintenance (R&M)
20% 2000
However, 1/3 spent unnecessarily
2000 wasted!!!
Maintenance costs have risen between
1800 10%
10% to 15%!!!
70%
1600
1400
• 14% of GDPBACKLOG PM TRACKING

1200
lost opportunity due to improper 1000
100%RELIABILITY &MAINTABILITY
DISCIPLINE GLOBAL1000
SURVEY 90%
(R&M) practices 800 80%
2-8 Weeks
70%
600 <2 Weeks
60%
200 8-16 Weeks
34%
400 50%
NOT SATISFIED PARTIALLY SATISFIED SATISFIED
• Increased losses up to 20%200or over USD 2.5 Trillion
50% 40%
30%
4-12 Months
> 1 Year
0
16%
20%
10%
1979 0%
2014
• In 2009, R&M industry approximates USD 1.2 Trillion
1979 with
2014 USD 750 Billion
Period of Backlog
direct costs of breakdowns, generally poor, incorrect, or excessive practices

TRACKED WEEKLY TRACKED OTHER DON'T KNOW
Maintenance
Global Trend on Maintenance and Reliability – US
Case
• “Maintenance Entropy” Maintenance Spare Parts – 40%-60% of the
• 90% of maintenance initiatives Total
fail Maintenance Budget
• 57% of CMMS applications fail 60%
• 93% of motor management programs fail

60%
50%
50%
40%
40%
• Proper R&M Practice 30%
• Improve energy costs
20%
of up to 122 Billion KWH and greenhouse gas
emission reductions of over 74 Mega-tons
10%
0%
Low Medium High
Low Medium High

Maintenance
Human Error

Maintenance
Nuclear Industry Root Cause of Failure
Design error 35% [people induced problems - not
calculation errors]
Random component failures 18% [process/procedure problems]
Operator error 12% [people/procedure problems]
Maintenance error 12% [people/procedure problems]
Unknown 12%
Procedure error & (procedure) 10%
unknowns
Fabrication error 1% [people/procedure problems]
Total 100%
Note: Early in the life of nuclear power plants

Maintenance
Nuclear Industry Root Cause of Failure
People 38%
Procedures & Processes 34%
Equipment 28%
Total 100%
Note: Mature nuclear power plants

Maintenance
MANKIND versus MACHINES
“Machines and their parts are built to work within fine tolerances, and specific
environments, and if not kept within those limits they will rapidly fail.”
AND RIGHT HERE IS WHERE ALL THE TROUBLE STARTS … We do not fulfil our
obligations to our machines
Machines Cannot Forgive Our Mistakes

It’s not ‘rocket science’. You just need to understanding that a machine
requires we humans to build it so the internal tolerances are accurate,
set it up accurately so it’s not distorted, and make sure it always runs
within those limits.

Maintenance
“It must be the Gremlins in my
machines.”
All these machine problems
did not need to happen. Once Not Flat
Poor Installation Out of Round
people get involved in making
choices, the risk of poor
Overloaded Over-lubricated
outcomes rise. The
‘HUMAN ELEMENT’ is
Contaminated
the uncertain, random results
from peoples’ actions and
behaviors. In our Unbalanced
ignorance we become the
‘GREMLINS’ that cause Misaligned
Over-tensioned
our machines to fail.
20
Blocked Suction
Basic Foundation No Screening
of Reliability Centered
Maintenance
The Odds are Against Us Doing it Right!
 Only one way to

disassemble
 40,000+ ways to
incorrectly
reassemble!
Source: Federal Aviation Authority, Human Error CD,
2008

Maintenance
Nuclear Plants: 88 –72%
Barringer, H. Paul, ‘Use Crow-AMSAA Reliability Growth
Plots To Forecast Future System Failures’
Boiler Accidents: 82%

(USA, ASME Report 2002)
Dams: 90%
(Henry, P., ‘Design Paradigms: Case Histories of Error and
Judgment in Engineering’)
80% of Failure
Events are Caused
by Human Factors
and Human Error
Maintenance
Japan’s Shinkansen Maintenance

Maintenance
Origin of RCM and Evolution
of Failure Pattern

Maintenance
How RCM
started…
• Inspections
o Looking for “potential failure” condition
o Leaves item in-service for most of its
useful life
• “Fly to failure”
o When consequences are severe - not an
option
o When consequences are acceptable - “fly
to failure” may be best approach for
cost/mission
• Maintenance Steering Group (later coined
RCM) applied the most appropriate
maintenance philosophy to each failure mode
based on data/information
Maintenance
Evolution of Asset Failures

Maintenance
History of RCM

Maintenance
Patterns A & B exhibit
a distinct wear-out
Nowlan and Heap’s zone – Beneficial to
United Airlines’ Age – Age Related
Reliability patterns Maintenance
for nonstructural Technology
equipment
These results came as a

surprise to almost everyone—
and continue to do so today Reliability-centered
when people see these results

Maintenance, F. Stanley
Nowlan and Howard F. Heap,
December 29, 1978, U.S.
for the first time. Department of Commerce,

National Technical
Information Service.

Maintenance
Individual Parts Reliability Curves
Six Failure Patterns and the Percentage of Component Because failure is
probabilistic for 75% -
Age-Related Failures Non-Age Related Failures 90% of parts, i.e. their
failure is a chance
event, this makes
Total 10% 25% Total 90% 75% replacement of those
parts on a certain date
Airline 3 - 4% - Naval 2 - 3% Airline 7 - 11% - Naval 6 - 9% totally pointless. If the
Bath Tub Break-in Period
part did not show
evidence of failure
then it could have
Airline 1 - 2% - Naval 10 - 17% Airline 14-15% - Naval 42- remained in operation
56% for a very long time.
Wear-out Random You spent money
unnecessarily
Airline 4 - 5% - Naval 3 - 17% Airline 66-68% - Naval 6-29% replacing a part that
had nothing wrong
Fatigue Infant Mortality with it.
The 1978 study by Nolan and Heap identified 68% of aircraft parts were pattern F, with
high Infant Mortality and then random failures over time. We learnt that every time we do
a repair we introduce a new chance of Infant Mortality
Research
29
by the USA merchant and military navy confirmed the presence of the failure Basic Foundation of Reliability Centered
patterns found in the aviation industry. Maintenance
History of RCM

Maintenance
Origin of RCM
• RCM success in Aviation industry

noted by other industries -
Nuclear Power industry adopts
approach due to focus on
avoiding “safety consequences”
while reducing costs
• “RCM II” by John Moubray
published in UK in 1990
• “Reliability-Centered
Maintenance” by Mac Smith
published in US in 1993
• As interest in increased, a variety
of other processes called
themselves “RCM”
• Industry interest in SAE JA1011
and JA1012 was to identify
“valid” RCM approaches
Maintenance
Asset Life Cycle Stage:
Operations & Maintenance

Maintenance
ASSET
LIFE
CYCLE

Maintenance
ASSET LIFE CYCLE…
“…Interval that commences with

the identification of the need for
an asset and terminates with the
decommissioning of the asset or
any liabilities thereafter…”
A Clock
Maintenance
What is ASSET MANAGEMENT?
Coordinated activity of an organization to realize value from assets
Realization of value will normally

involve a balancing of costs, risks,
opportunities and performance
benefits…
• Application of the elements of the

asset management system
• Approach, the planning, the plans
and their implementation.
Note: According to ISO 55000 Definition

Maintenance
What is ASSET MANAGEMENT?
Set of activities associated with:
 Identifying what assets are needed,

 Identifying funding requirements,
 Acquiring assets,
 Providing logistic and maintenance
support for assets,
 Disposing and renewing assets,
so as to effectively and efficiently meet the REALIZING

desired objective VALUE
Maintenance
Stakeholders
Capability Delivery Model

Needs
Analysis
Systems Engineering Acquisition Operations & Maintenance
Demand Non-Asset
Analysis Solutions
Concept
Validation
Asset Solutions
Needs Concept Support Integrated

Specification Design Operations
Solution Exploration Analysis Support
Maintenance
Create and
Demand Dispose
Management
Requirements Engineering Support Process

Process Audit
Change Change Change Monitoring
Continuous
37 Improvement Configuration Management
Basic Foundation of Reliability Centered
Maintenance
Physical Asset Management
Systems Operations &

Acquisition
Engineering Maintenance
Create & Configuration Continuous

Improvement
Dispose Management
LEADERSHIP
NON-ASSET Stakeholders’
&
SOLUTION Management COMMITMENT

Maintenance
Asset Management and the Asset
Management System
Coordinated activity of an
Managing the
organization to realize value from
Organization
assets
Asset Set of interrelated or interacting elements
Management
to establish asset management policy,
Asset asset management objectives and
Management processes to achieve these objectives
System
Asset
Portfolio Assets that within the scope of the
asset management system
Asset An item or thing that has potential

(Individual)
or actual value to an organization

Maintenance
Stakeholders
Capability Delivery Model

Needs
Analysis
Systems Engineering Acquisition Operations & Maintenance
Demand Non-Asset
Analysis Solutions RCM shall be Introduced as a
Maintenance Strategy
Concept
Validation
Asset Solutions
Needs Concept Support Integrated

Specification Design Operations
Solution Exploration Analysis Support
Maintenance
Create and
Demand Dispose
Management
Requirements Engineering Support Process

Process Audit
Change Change Change Monitoring
Continuous
40 Improvement Configuration Management
Maintenance
Operation & Maintenance Stage
• By far, the most enduring stage of the O&M modeled as PAIR –

Asset life cycle alone, neither maintenance
• Begins as soon as an Asset is accepted & operations deliver the
and entered into service and ends with requisite asset outputs and
the decision to dispose the Asset levels of service, and BOTH
• CONSUMES the LARGEST portion of NEED EACH OTHER.
the ASSET COST.
• FOCUS is on the USE of Assets to
provide a defined service, and on their
MAINTENANCE and support to ensure
a continuing capability with respect to
service provision, safety and reliability
• Stage which emphasizes on the
PRESERVATION OF ASSETS
Maintenance
Objectives of Operation & Maintenance Stage
Maintenance Operation
Ensure realization of the Like Maintenance, requires the
required safety and reliability development and execution of
levels of the Asset, at a approved tasks; and
MINIMUM TOTAL COST, Only approved persons are able
commensurate with the to execute assigned operations
organization’s business plan. tasks.

Maintenance
An Illustration…
In Adopting Asset Management, say using for
Strategic Acquisition for Replacement or
Modification of an Asset
Current Asset’s Performance Life Cycle Perspective
Same Performance
Or
MRO Cost
Performance Better Performance
MRO
Cost
Increased Operating
Operating Life Lower MRO
Life
Age Age

Maintenance
Physical Asset Management Case Study

Maintenance
Workshop 1
• LIST COMMON MAINTENANCE CONCERNS
• WHAT ARE THE BENEFITS OF PHYSICAL ASSET
MANAGEMENT IN YOUR ORGANIZATION? GIVE
AT LEAST FIVE (5) BENEFITS.

Maintenance
Some Common Maintenance Problems
1. Insufficient Proactive 8. Blind Acceptance of OEM
Maintenance Inputs
2. Frequent Problem Repetition 9. Variability Between Like Units
3. Erroneous Maintenance Work 10. Effective Use of Predictive
4. Sound Practices Not Maintenance
Institutionalized 11. 80/20 Rule – Not in Use
5. Sketchy Rational For PM 12. Reluctance to Spend Upfront $
Actions
6. PM Often Conservative - Or
Unnecessary
7. Lack of Visibility and
Traceability

Maintenance
Benefits of Physical Asset Management
1. REDUCE the total costs of operating their assets
2. REDUCE the capital costs of investing in the asset base
3. REDUCE the potential health impacts of operating the assets
4. REDUCE the safety risks of operating the assets
5. REDUCE legal risks associated with operating assets
6. IMPROVE the operating performance of their assets (reduce failure
rates, increase availability, etc.)
7. MINIMIZE the environmental impact of operating the assets
8. MAINTAIN AND IMPROVE the reputation of the organization

Maintenance
MAINTENANCE &
MAINTENANCE
MANAGEMENT

Maintenance
Definition of Maintenance
It includes servicing, test, inspection,
adjustment/alignment, removal,
replacement, reinstallation,
troubleshooting, calibration, condition
determination, repair, modification,
overhaul, rebuilding, and reclamation.
Ensuring that physical assets

continue to do what their intended
users want them to do, this is a
function of keeping physical assets
in or restoring them to serviceable
condition.
Maintenance
Maintenance Times
Run-down Ramp-up
Preparation and/or
Waiting
and/or Delay
Active Maintenance
Delay
Time
OPERATIONAL STATE
Up Time Down Time Up Time
Time of
Failure
TIME

Maintenance
Maintenance Times
Run-down Ramp-up
Preparation and/or
Waiting
and/or Delay
Active Maintenance
Delay
Time
Part of the MAINTENANCE TIME during

OPERATIONAL STATE
which a maintenance action is performed on

Up Time Down Time Up Time
an item, either automatically or manually,
Time of excluding logistic delays
Failure
TIME

Maintenance
Types of Maintenance – A Review from AM
Perspective
Maintenance Preventive Condition
Defects
Objectives Maintenance Monitoring
Hard Time
Activity
Functional
Testing
Corrective Repair Unplanned

Maintenance (Standards) Repairs
Planned
Repairs
Renewal
52 (Cost) Maintenance
Types of Maintenance – A Review from AM
Perspective
Maintenance Preventive Condition
Defects
Objectives Maintenance Monitoring
FUNCTIONAL FAILURE:
• Manages Operational Risk in that MONITORING:
CONDITION • Where the functional
it is safety-and-reliability-focused
• Applicable to individualCONDITIONAL
element FAILURE:
Hard Time specification has been
and not cost focused that is examined to see• of
Representative
the of unacceptable
exceeded, such as leak rate
• Tasks that Include scheduled Activity
asset will continue to work future probability of failure and
untilor
HARD TIME ACTIVITY: limits input voltage or signal
maintenance to retain a system or generally
the next examination; strength degradation managed as defects
• Applicable to a population of below
product in a specified condition.
• E.g. Vibration analysis, and registered for monitoring and
equipment that is serviced operable
in repairlevels resulting in loss
Functional
consumable future
fluid measurements,
of specified capability;
someway, removed and • Repair criteria should be based
amount ofTesting
wear or misalignment
repaired/overhauled or•else These are generally (or
on criticality and anticipated rate
of parts, size of cracks ortemporarily)
depths fixed;
removed and thrown away or as
deterioration.
of surface corrosion • E.g. replacement of failed circuit
RENEWAL:
Corrective uneconomically
Repair repairable; Unplanned
•• Addresses the decreaing cost
cards,
E.g. cleaning filters, replacing switch open circuits,
Maintenance (Standards)
effectiveness of an existingruptured pressure Repairs
vessels, failed
electrolytic
• Returns failed Asset to specified capacitors or
‘examine
lubricants,and repair’ routine
overhauling pressure piping, etc.
complex
condition.
maintenance
equipment where strategy caused
loads are by Planned
loss of general
inconsistent andcondition of the
can be related
asset;
Repairs
to time
• Return to As New;
Renewal Analysis
• Driven by Cost Benefit
53 (Cost) Maintenance
Asset Time Breakdown to Maintenance
Times
Time Available
Actual Running Unavailable to

Idle Time
Time Run - Downtime
Scheduled Unscheduled
No Demand Downtime Downtime
PM/PdM Repairs
No Feedback or
Operational
Logistics Repair Other
Administrative
Modifications Modification
(Not Scheduled
for Operation)
Set
Basic up
Foundation of Reliability Centered
54
Maintenance
Equipment
Time
Breakdown
to
Maintenance
Times

Maintenance
Thus, In Defining MAINTENANCE MANAGEMENT…
“the effective, efficient,

ECONOMICAL
LEADERSHIP of people
and the utilization of
financials, materials, time,
and space to ACHIEVE
Maintenance
Predetermined
Objectives.”
Maintenance
RELIABILITY, AVAILABILITY &
MAINTAINABILITY (RAM)

Maintenance
Overview of Reliability

Maintenance
Signs
Everywhere…

Maintenance
Reliability…
 Ability of an item to
perform a required
function under given
conditions for a
given time interval.
ISO 14224:2006(E)
Petroleum, petrochemical and natural gas
industries — Collection and exchange of
reliability and maintenance data for physical
asset

Maintenance
What is meant by Reliability?
That is, it properly
Probability is the
performs the job it is
same as ‘chance’
meant to do
Reliability is the probability an item will function Reliability=Chance of

correctly when needed, for the period required, in Success
the specified environment. The reliability of a part, or of
a whole machine, or system
In other words for in service depends on:
How reliable is this glass?
a set amount of 1. Robustness of the Design to
• This means what is the time Lack of Manufacturing
chance that this glass will Precision
hold water the next time 2. Precision and Accuracy in
you want to use it? Manufacture and Assembly
• If this glass is broken, then
3. Roughness of Loading in
it will not be available to
Operation
you to use – it will have
failed. 4. The Quality, Relevance and
61 Basic Foundation of Reliability
TimingCentered
of Maintenance
Maintenance
Reliability Engineering Terms
• Function • Failure Mechanism
 verb-noun combination which describes  Processes by which failure modes are
the purpose of a design induced.
• Failure • Requirement
 Termination of the ability of an item to  A function performing with a certain
perform a required function characteristic
• Failure Mode (Dominant) • Failure Site
 Manner in which an item fails (theoretical
 Physical location where the failure
focus, historic failure or experienced
mechanism is observed to occur, and is
event).
often the location of the highest stresses
• Failure Effect and lowest strengths.
 Consequence of a failure mode on the

operation, function or status of the item

Maintenance
Reliability Requirements
• How often do failures occur,
• For how long do the
failure‐caused
out‐of‐service or
degraded‐service
conditions (outages)
persist,
• Life cycle costs, and
• What is the impact of
failures on the customer
and on the business.
Maintenance
Series Arrangement of
Parts Allow a Shaft to Turn
in a Electric Motor Bearing
Housing
Note:
• When you look closely at how the assembly is

built, you find that it is configured such that
parts work with others in a sequence.
• It identifies a portion of the sequence of parts
that allow the shaft to turn in the bearing.
• Notice that they are organized in a series
arrangement.
Shaft Shaft Inner Roller Outer Housing

Lock Nut Lube
Seal Journal Race Bearing Race Bore

Maintenance
Planning Greatly Improves the Odds
of a Series Work Process Being Done
Right
The Job
Rjob=
Task 1 Task 2 Task 3 Task 4 Task 5
R1 x R2 x R3 x R4 x R5
• Remember this …? • We plan maintenance in great
detail because there is no
• We have a series redundancy.
process. 1 1 1 n
• The only way to do a 100%
• One fails … all fails! One reliable job is to make sure
poor … all poor! Rsystem= R1 x R2 x R3
every part of it is done reliably.
Before planning 0.95 x 0.95 x 0.95 x 0.95 x 0.95 = 0.77
After planning 0.99 x 0.99 x 0.99 x 0.99 x 0.99 = 0.95
65 Planning Reduces the Human Error

Basic Foundation Rate
Maintenance
Calculating The Reliability of Systems
This is important
to understand.
• Series Systems Success really
does depend on
it!
1 1 1 n
Rsystem= R1 x R2 x R3 … Series system reliability is always lower than
the LEAST reliable item
1
• Parallel Systems 1
Rsystem= 1 - [(1-R1) x (1-R2) x (1-R3) …] 1
• The reliability of systems of equipment can be calculated mathematically.

• The maths also applies to the reliability of processes. n
Parallel system reliability is always higher than the

MOST reliable item
Maintenance
Reliability
of Parts and
Systems of
Parts

Maintenance
Series Arrangement of Parts Allow a Shaft to
Turn in a Electric Motor Bearing Housing
Shaft Inner Roller Outer Housing

Shaft Seal Lock Nut Lube
Journal Race Bearing Race Bore
The Reliability of a Series Arrangement Depends on the Reliability of its Components

Shaft Seal Lock Nut
Every Part in a Asset has its Own Reliability

Shaft Seal Lock Nut
R1 R2 R3 R4 R5 R6 R7 R8
Maintenance
Series Arrangement of Parts Allow a Shaft to Turn in a
Electric Motor Bearing Housing
Every Part in a Machine has its Own Reliability
Rseries = R1 x R2 x … x
As Illustration RN

Maintenance
What is meant by Reliability?
That is, it properly
Probability is the
performs the job it is
same as ‘chance’
meant to do
Reliability is the probability an item will function Reliability=Chance of

correctly when needed, for the period required, in Success
the specified environment. The reliability of a part, or of
a whole machine, or system
In other words for in service depends on:
How reliable is this glass?
a set amount of 1. Robustness of the Design to
• This means what is the time Lack of Manufacturing
chance that this glass will Precision
hold water the next time 2. Precision and Accuracy in
you want to use it? Manufacture and Assembly
• If this glass is broken, then
3. Roughness of Loading in
it will not be available to
Operation
you to use – it will have
failed. 4. The Quality, Relevance and
70 Basic Foundation of Reliability
TimingCentered
of Maintenance
Maintenance
How do you Measure Reliability
of a Glass?
Since reliability is the
‘chance’ that the glass will
still be usable, we can Because we know the
measure reliability ‘in ways the glass can fail
reverse’ by working out the (its failure mechanisms),
chance it will fail. we can estimate it’s
chance of failing (i.e.
being broken – which is
Reliability
its failure mode) in a
Failure
Chance of Failing
period of time. What is

left over is the chance of
not failing – its Reliability.
t1
Time or Service
Maintenance
Remaining Life Left in a Part
The distribution of
Reliability
failure history of many
Failure
of the same part is By collecting real data from
determined by design, use in-the-field we can draw
environment and the chance of failure curve
100%
operation for a part in its working
environment, under the
Chance of Failure of Part
service practices it lives in.

At the time of ‘t1’ At time ‘t1’ these We can say that any
all these parts parts are still identical part put into those
have failed operating circumstances will behave
the same way and so
estimate its remaining life.
t1 Time Age of Part or Usage

Maintenance
Remaining Life Left in a Part
The distribution of
Reliability
failure history of many
Failure
of the same part is The area under the ‘Chance
determined by design, of Failure’ curve either side
environment and of t1 lets us calculate how
100%
operation many identical parts will
likely fail and how many are
likely to still be operating.

At the time of ‘t1’ At time ‘t1’ about We say ‘likely’ because we
about 50% of 50% of parts are are talking about ‘chance’,
parts have failed still operating which is never totally
controllable (Or is it?).
t1 Time Age of Part or Usage

Maintenance
Chance of a Part Surviving Another Month
Between time ‘t1’ and

‘t2’ about 10% more
parts will fail, which is This area is
The whole curve is
about 20% of the parts called ‘Reliability
pdf called ‘Probability
remaining in service Function’
Density Function’ With a ‘Chance of
Failure’ curve we
can estimate how
At the time of ‘t2’ At time ‘t2’ about many parts still in
about 60% of 40% of parts are service at a certain
parts have failed still operating time are likely to be
in service after
(say) another
month goes by, or
for any other length
One
month
Time Age of Part or Usage of time.
t 1 t2

Maintenance
Cumulative Distributions
The whole curve is Hazard function for the
called ‘Probability days of survival of
Density Function’ organ transplant
patients
Cumulative Hazard
Function
The whole curve is called
‘Cumulative Distribution
75 Function’ Basic Foundation of Reliability Centered
Maintenance
The Reliability of Reliability is Not High –
Confidence Limits
Reliability should never be used to set operating and maintenance
policies. It is the result of operating and maintenance policies!
• Don’t use Reliability Prediction of the Future… it is not repeatable

• Use Reliability to make comparisons between options
Predicted Failure Rate

60% 60% 60%
90% 90% 90%
95% 95% 95%
λ λ λ
1.5λ 2.5λ 3λ
2.5λ 4λ 6λ
3.5λ 5λ 8λ
Source: Smith, Dr, David J., Confidence of Confidence of Confidence of
Reliability, Maintainability
and Risk, Seventh Edition,
Prediction using Site Prediction using Prediction using
Elsevier, 2005, Section 4.4 Specific Data Industry Database Generic
Basic Databases
Foundation of Reliability Centered
76
Maintenance
What is the Reliability of this Drinking Glass?
In other words: ‘What’s the chance it will hold water next time you use it?’
What can cause this glass to break?

Understanding how to • It can be dropped, for example -
measure reliability is 1. slip from your hand
2. fall off a tray
one of the most 3. slip out of a bag or carry box
important concepts • It can be knocked,
that we need to know 1. hit by another glass
of to do maintenance 2. clanked when stacked on each other
3. hit by an object, like a plate or bottle
well.
• It can be crushed,
1. jammed hard between two objects
2. stepped-on
These many ways 3. squashed under a too heavy object
for the glass to • It can be temperature shocked,
break (the failure 1. in the dish washer
2. during washing-up
mode), are called • Mistreated,
‘failure 1. It can be thrown in anger
mechanisms’. 2. It can be smashed intentionally
• Latent damage
1. scratched and weakened to later fail more easily
2. chipped and weakened to later fail more easily

Maintenance
Chance of Failure for a Drinking Glass
• It can be dropped, for example -

1 1. slip from your hand
1,000,000 glasses sold in packs of 12 2. fall off a tray
83,333 households buy a pack of 12 3. slip out of a bag or carry box
Say average household breaks 2 glasses a year • It can be knocked,
Failure Rate per Year
1. hit by another glass

That is 166,667 glasses broken each year which are then replaced 2. clanked when stacked on each other
Chance of breaking a glass during a year is 166, 667 ÷ 1,000,000 3. hit by an object, like a plate or bottle
+ • It can be crushed,
Chance of Glass Failure Curve + 1. jammed hard between two objects
+ 2. stepped-on
+ 3. squashed under a too heavy object
0.167 • It can be temperature shocked,
+ Crushed - squashed
1. in the dish washer
+ Crushed - jammed
+ Mistreated - smashed
• Mistreated,
+ Dropped - tray 1. It can be thrown in anger
+ Knocked - stacked 2. It can be smashed intentionally
+ Knocked - hit • Latent damage
Dropped - hand 1. scratched and weakened to later fail more easily
0 2. chipped and weakened to later fail more easily
0 24 48 Time (months)
‘Opportunity’ for
breakage arises
regularly
Maintenance
Stop Breakage = Remove Failure Causes = Improved
Reliability
Design Change
1
• It can be dropped, for example -
1. slip from your hand
Failure Rate per Year
2. fall off a tray
3. slip out of a bag or carry box
• It can be knocked,
Procedure Change 1. hit by another glass
2. clanked when stacked on each other
3. hit by an object, like a plate or bottle
Instructions &
×
• It can be crushed,
Training
1. jammed hard between two objects
2. stepped-on
0.167 3. squashed under a too heavy object
• It can be temperature shocked,
1. in the dish washer
$ $ $ $
• Mistreated,
1. It can be thrown in anger
0.045 2. It can be smashed intentionally
+ Mistreated - smashed • Latent damage
+ Knocked - hit 1. scratched and weakened to later fail
more easily
Dropped - hand 2. chipped and weakened to later fail
0 more easily
0 12 24 Time (months)
‘Opportunity’ for
breakage arises
regularly
Maintenance
Workshop 2: Over-
Stressing Steel Parts

Maintenance
Over-Stressing
No Failure Mode Test Procedure Cycle Count
Steel Parts
1 Bending stress
fatigue
 Use your thumb and pointer finger of

each hand and pull the two end loops of
the clip apart as far as possible so the
centre bend straightens up.
 Bend the clip back and forth from fully
open through to touching the fingers.
 While counting the number of cycles
repeat the open-close cycle until the wire
breaks. Record the cycle count.
2 Torsional stress
fatigue
 Use your thumb and pointer finger of each

hand and pull the two end loops of the clip
open to the 90 degree position.
 Hold one loop in your hand and rotate the
other leg 360 degrees.
 While counting the number of cycles
repeat the rotation cycle until the wire
breaks. Record the cycle count.

Maintenance
Paper Clip Failure Distribution Curve
Uncoil a paper clip and 1) bend it and 2) twist it as instructed by the
Presenter. Carefully count the number of cycles until it breaks.
Develop a distribution of the count of the number of

1) bending and
2) torsion cycles to failure.
1
4
1
3
1
2
1
1
No of Failures
1
0
9
8
7
6
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 6
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
No of Cycles

Maintenance
Stress-Life Cycle Curve
• This graph is called a stress-life cycle curve. A great deal of fatigue load
testing, where the load cycles in one direction and is then reversed, has
been done with a wide range of metals. From these tests graphs of tensile
strength verses number of cycles to failure have been developed. An
example of one for wrought (worked) steel is shown in the Figure. It helps
us to understand how much load a material can repeatable take and still
survive.
• Have you ever bent a metal wire back and forth until it breaks from being
worked? If you have then you were performing a stress life-cycle test. The
wire does not last long when bent to 90 degrees one way and then back 90
degrees the other way. Each bend was an overstress, and eventually the
overstress accumulated and the wire fatigued and failed.
• The vertical scale on this log-log plot shows the applied stresses as a
proportion of the steel’s ultimate tensile stress ‘Su’ while the horizontal
scale is the number of stress cycles to failure. The left hand sloping line
tells us is that a steel part put under high cyclic loads producing stresses in
high proportion to its ultimate tensile stress will fail after a given number of
cycles. Whereas the right hand side of the curve indicates that if cyclic
stresses are maintained below a definable limit the part will have infinite
life. The curve also tells us that a steel part made of this metal will fail if it
has just one load cycle with a stress greater than its ultimate tensile
strength. (Like when a small bolt snaps-off if over-tightened) It will also fail
in less than two thousand cycles if the imposed stresses are 90% or more
of the tensile strength. But if the stresses are kept below half of the tensile
strength it will never fatigue.
• Note that not all metals have a fatigue limit.

Maintenance
Stress at the Atomic Level Destroys
Uncoil a paper clip and 1) bend it and 2) twist it as instructed by
the Presenter. Carefully count the number of cycles until it
breaks.
No of Stress Cycles Before Failing

Proportion of Ultimate Stress
Failure For long operating
life, parts need to
for Wrought Steel
stay below the infinite
Failure life atomic stress
level
2,000 cycles at 200,000 cycles at Infinite cycles at

this stress level this stress level this stress level
Have you ever bent a metal wire back and forth until it breaks from being worked? If you have then you were performing a stress life-
cycle test. The wire does not last long when bent to 90 degrees one way and then back 90 degrees the other way. Each bend was an
overstress, and eventually the overstressing accumulated as damage to the microstructure and the wire fatigued and failed. The very
same thing happens with the parts in a machine. If you want your parts to NEVER FAILBasic
FROM OVERSTRESS
Foundation – KEEP OPERATING
84 STRESSES BELOW INFINITE LIFE LEVELS. Maintenance
Overview of Maintainability

Maintenance
Maintainability…
 Ability of an item under given conditions of

use, to be retained in, or restored to, a
state in which it can perform a required
function, when maintenance is performed
under given conditions and using stated
procedures and resources.
 Probability that a failed item will be
restored to operational effectiveness
within a given period of time when the
repair action is performed in accordance
with prescribed procedures.
‘Probability of Repair in a Given

Time’

Maintenance
Difference Between Maintenance and Maintainability
Maintainability Maintenance
o Measures or steps taken during the o Measures taken by the product users for
product design phase to include features keeping it in operational state or repairing
that will increase ease of maintenance it to operational state
and ensure that the product will have
minimum downtime and life cycle support
costs when used in field environments
oDesign parameter intended to minimize oAct of servicing and repairing equipment

equipment repair time

Maintenance
General Principles of Reliability and Maintainability
No. Maintainability Reliability

1 Reduce life cycle maintenance costs Maximize the use of standard parts
2 Reduce the amount, frequency, and Use fewer components for performing
complexity of required maintenance tasks multiple functions
3 Reduce mean time to repair (MTTR) Design for simplicity
4 Determine the extent of preventive Provide adequate safety factors between
maintenance to be performed strength and peak stress values
5 Provide for maximum interchange ability Provide fail-safe designs
6 Reduce the amount of supply supports Provide redundancy when required
required
7 Reduce or eliminate the need for Minimize stress on components and parts
maintenance
8 Consider benefits of modular replacement Use parts and components with proven
versus part repair or throwaway design reliability
built-in design and installation characteristic
Maintenance
General Principles of Reliability and Maintainability
No. Maintainability Reliability

1 Reduce life cycle maintenance costs Maximize the use of standard parts
2 Reduce the amount, frequency, and Use fewer components for performing
complexity of required maintenance tasks multiple functions
3 Reduce mean time to repair (MTTR) Design for simplicity
4 Determine the extent of preventive Provide adequate safety factors between
maintenance to be performed strength and peak stress values
5 Provide for maximum interchange ability Provide fail-safe designs
6 Reduce the amount of supply supports Provide redundancy when required
required
7 Reduce or eliminate the need for Minimize stress on components and parts
maintenance
8 Consider benefits of modular replacement Use parts and components with proven
versus part repair or throwaway design reliability
built-in design and installation characteristic
Maintenance
Maintainability Function
𝒕
M(t) = 𝒇
𝟎 𝒅𝒓
𝒕 𝒅𝒕
Where t is time, Fdr (t) is the probability density function of the repair time, and M(t)
is the maintainability function.
MAINTAINABILITY FUNCTION FOR EXPONENTIAL

DISTRIBUTION
𝟏
− 𝑴𝑻𝑻𝑹 𝒕
Me(t) = 1 -𝒆
Where MTTR is the Mean Time To Repair.
PROBABILITY DISTRIBUTIONS PLAY AN IMPORTANT

ROLE IN MAINTAINABILITY ENGINEERING

Maintenance
Sample of Maintainability Function For Exponential Distribution
Computation
Assume that the repair times of a mechanical system are exponentially distributed with a
mean value of 5 hours. Calculate the probability of completing a repair in 6 hours.
Solution:
𝟏 Where MTTR is the Mean Time To Repair.
− 𝒕
Me(t) = 1 -𝒆 𝑴𝑻𝑻𝑹
𝟏
− 𝟔
Me(6) = 1 -𝒆 𝟓
𝟔
−
Me(6) = 1 -𝒆 𝟓
M = 0.6988
This means there is a likelihood of approximately 70% that the

repair will be completed within 6 hours.

Maintenance
Overview of Availability

Maintenance
Defining Availability
• Probability that an asset will, when used
under specified conditions, operate
satisfactorily and effectively;
• Percentage of time or number of
occurrences for which an asset will
operate properly when called upon;
• Proportion of total time that an item of
equipment is capable of performing its
specified functions, normally expressed
as a percentage.
• Can be calculated by dividing the
equipment available hours by the total
number of hours in any given period.

Maintenance
Operational Cycles for Intrinsic and System Availability
Operational Availability - Measures the "REAL" average

availability over a period of time and includes all
experienced sources of downtime, such as administrative
downtime, logistic downtime, etc.
Intrinsic availability is defined as consisting only of Instantaneous availability, A(t), is defined

the actual active repair time and neglects any as the probability that a system will perform
other logistic or personnel factors. a specified function under given conditions
at a prescribed time.

Maintenance
Operational Cycles for Intrinsic and System Availability

Maintenance
MEAN TIME BETWEEN FAILURE, MEAN TIME TO FAILURE (MTTR) & MEAN
TIME TO FAILURE
MTBF is a key reliability metric for systems that can be repaired or that can be restored.
MTTF is the expected time to failure of a system.
Non-repairable systems can fail only once, hence for non-repairable items,
MTTF is equivalent to its mean of its failure time distribution.
Repairable system can fail several times, while non-repairable can fail only once.
MTBF
x x
A B
MTTR MTTF MTTR
Point where Total time it Point where

a new part will take for the new part
is installed the part to fail will fail again
Time to repair
Point where the
Point where the HENCE : MTBF = MTTR + MTTF 2nd failure occurs
1st failure occurs
Maintenance
Availability
and
Reliability of
a Single
Event

Maintenance
Availability
as a Function
of MTBF and
1/MTTR

Maintenance
Relationship of Availability, Maintainability
and Reliability
Reliability = F(Maintainability) + F(Maintenance Parameters)
Availability = F(Reliability) + F(Operational Parameters)

Reliability
Availability = F(Maintainability) + F(Maintenance Parameters) +

F(Operational Parameters)

Maintenance
Reliability:
extension of quality into
the time domain and may
be paraphrased as ‘the
probability of non-failure in
Reliability
a given period’.
Availability:
probability that an item
is available for
Maintainability
application or use when
needed.
Availability
Maintainability:
probability that a failed item
will be repaired to its
satisfactory working state.

Maintenance
End of Module
U p N e x t … .
M o d u l e 2

Maintenance

RCM - Module 1 11-13-17 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

RCM - Module 1 11-13-17 PDF

Uploaded by

Copyright:

Available Formats

Reliability-Centered Maintenance –

1 Basic Foundation of Reliability Centered

2 Basic Foundation of Reliability Centered

3 Basic Foundation of Reliability Centered

4 Basic Foundation of Reliability Centered

“METHOD to identify and “A LOGICAL, STRUCTURE

5 Basic Foundation of Reliability Centered

6 Basic Foundation of Reliability Centered

7 Basic Foundation of Reliability Centered

2. FUNCTIONAL FAILURE ANALYSIS

Failure Mode Effect

10 Basic Foundation of Reliability Centered

11 Basic Foundation of Reliability Centered

13 Basic Foundation of Reliability Centered

• 14% of GDPBACKLOG PM TRACKING

direct costs of breakdowns, generally poor, incorrect, or excessive practices

• 93% of motor management programs fail

15 Basic Foundation of Reliability Centered

16 Basic Foundation of Reliability Centered

Note: Early in the life of nuclear power plants

17 Basic Foundation of Reliability Centered

Note: Mature nuclear power plants

18 Basic Foundation of Reliability Centered

Machines Cannot Forgive Our Mistakes

19 Basic Foundation of Reliability Centered

 Only one way to

21 Basic Foundation of Reliability Centered

Boiler Accidents: 82%

23 Basic Foundation of Reliability Centered

24 Basic Foundation of Reliability Centered

26 Basic Foundation of Reliability Centered

27 Basic Foundation of Reliability Centered

These results came as a

when people see these results

for the first time. Department of Commerce,

28 Basic Foundation of Reliability Centered

30 Basic Foundation of Reliability Centered

• RCM success in Aviation industry

32 Basic Foundation of Reliability Centered

33 Basic Foundation of Reliability Centered

“…Interval that commences with

Realization of value will normally

• Application of the elements of the

Note: According to ISO 55000 Definition

 Identifying what assets are needed,

so as to effectively and efficiently meet the REALIZING

Capability Delivery Model

Systems Engineering Acquisition Operations & Maintenance

Needs Concept Support Integrated

Requirements Engineering Support Process

Systems Operations &

Create & Configuration Continuous

38 Basic Foundation of Reliability Centered

Asset An item or thing that has potential

39 Basic Foundation of Reliability Centered

Capability Delivery Model

Systems Engineering Acquisition Operations & Maintenance

Needs Concept Support Integrated

Requirements Engineering Support Process

• By far, the most enduring stage of the O&M modeled as PAIR –

42 Basic Foundation of Reliability Centered

Current Asset’s Performance Life Cycle Perspective

43 Basic Foundation of Reliability Centered