Professional Documents
Culture Documents
MAINTENANCE
References
DoDI 4151.22, December 2, 2007
NAVAIR 00-25-403, 1 March 2003
SAE JA-1011, August 1999
SAE JA-1012, January 2002
Boeing (2010) Statistical Summary of
Commercial Jet Airplane Accidents,
Worldwide Operations 1959-2009, Seattle
Moubray, J. (1997) Reliability-centered
Maintenance. New York: Industrial Press.
Overview
• Background
– Condition Based Maintenance
– Changing views of Maintenance
• History and background of RCM
• The RCM Process
• The RCM team
• The Seven Questions
• Results of the Analysis
What is RCM?
• Definition
– A process used to determine what must be done to ensure that
any physical asset continues to do what its users want it to do in
its present operating context
– Mitigate the consequences of failure
PREVENTIVE CBM/RCM
MAINTENANCE
BUILD HEAVY
Time Based
Reliability, Availability,
Maintainability, TOC
Views of Wear Out Patterns
Failure Patterns
Condition Based Maintenance
Origin of RCM
• Boeing 747 and United Airlines
– MSG-1 (Maintenance Steering Group)(1968)
– DC-8 required 4 million man hours per 20,000 flight hours
• (200 man hours per flight hour)
– Using RCM techniques 747 required 66,000 while improving
reliability
• (3.3 man hours per flight hour)
• MSG-2 & MSG-3 followed for many military and civilian aircraft
• Nowlan & Heap, RCM, 1978
• SAE standardized RCM requirements for industrial equipment with:
– JA-1011
– JA-1012
• NAVAIR standard – 00-25-403
Record of Improved Safety
The RCM Analysis Team
Maintenance
Officer
or Chief
Officer or Chief
Maintainer
The RCM Process
• Disciplined and highly structured
• Synergy created by the multifunctional team
• Collective wisdom of team members from all areas
– Operations
– Maintenance
– Engineer
– Logisticians
– Specialists
• Decisions based upon consensus
• Cross functional information sharing leading to deeper
understanding of the asset by all
The Seven Questions
1. What are the functions and associated performance
standards of the asset in its present operating context?
2. In what ways does it fail to fulfill its functions?
3. What causes each functional failure?
4. What happens when each failure occurs?
5. In what way does each failure matter?
6. What can be done to predict or prevent each failure?
7. What should be done if a suitable proactive task cannot
be found?
1. Functions
What are the functions and associated performance
standards of the asset in its present operating context?
– What do its users want the asset to do?
• Primary function – the main purpose the asset was acquired.
• Secondary functions
– Safety - Comfort
– Environmental - Appearance
– Control - Protection
– Containment - Economy/efficiency
– What is the Operating Context?
• Where, when, under what conditions
– What are the required performance standards?
• How much; how fast
Sample Function Statement
• PRIMARY FUNCTION - To pump water from tank X to
tank Y at not less than 800 gallons per hour at
temperatures ranging from 40 degrees F to 120 degrees
F.
• SECONDARY FUNCTION - To contain water within the
pump, not permitting leaks exceeding 1 ounce per 8 hour
work shift
• SECONDARY FUNCTION – To prevent any
contamination at all of the water from lubricating oil.
• SECONDARY FUNCTION – To shut off automatically if
the water in tank Y rises above 90% capacity to prevent
overflow
Initial Capability
Pump
1000 GPH
X Y
Output Output
800 GPH 800 GPH
4. Failure Effects (FMEA)
• What happens when each failure mode occurs?
– Evidence of failure
– What threat to safety or environment
– How does it affect operations
– What damage is done by the failure
– What must be done to repair the failure
• Consider “down time” vs repair time when measuring
effects
• Best sources of FMEA data are the users who work with
the asset daily
5. Failure Consequences
Output Output
800 GPH 800 GPH
Different Operating Context;
Different Failure Consequences
Primary
Pump
Standby
Pump
Standby
Pump