Reliability Centered Maintenance; Are we Ready

CONTENTS

What is RCM RCM Methodologies Applications & Requirements Conclusions & our Readiness

Reliability Centered Maintenance

Maintenance Trends

Reliability Centered Maintenance

Reliability Centered Maintenance

Preventive Maintenance
Whole sale implementation of PM recommendations, without considering equipment criticality or condition, may result in work load that is too large to achieve. consciously chosen, effectively implemented and properly documented maintenance programme seem to be an answer

Reliability Centered Maintenance

The Definition of Reliability

In the book Maintainability, Availability, and Operational Readiness Engineering Dimitri Kececioglu defines reliability as: "The probability that a system will perform satisfactorily for given period of time under stated conditions."

Reliability Centered Maintenance

The Definition of Reliability

Nowlan and Heap define Inherent Reliability as: "the level of reliability achieved with an effective maintenance program. This level is established by the design of each item and the manufacturing processes that produced it. "

Reliability Centered Maintenance

Simple Definition of RCM

Process to ensure that assets continue to do what their users require in their present operating context

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RCM involves
Establishment of Safe Minimum levels of Maintenance Changes to Operating Procedures & Strategies Establishment of Capital Maintenance Regimes & Plans

RCM Methodologies

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RCM is largely based on 7 steps

1. What are the functions of the asset? 2. In what way can the asset fail to fulfill its functions? 3. What causes each functional failure? 4. What happens when each failure occurs?

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RCM is largely based on 7 steps (cont.)

5. What are the consequences of each failure? 6. What should be done to prevent or predict the failure? 7. What should be done if a suitable proactive task cannot be found?

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Outcome of 7 RCM questions
What would be done to predict or prevent failure (Default Actions) What to be done if suitable proactive task cannot be found

Reliability Centered Maintenance Failure Management Strategies Selected based on

Established common failure patterns Failure Mode Effects Analysis (FMEA)

Reliability Centered Maintenance Failure Patterns

Reliability Centered Maintenance Simplified FMEA logic

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Failure Management Strategies
Schedule Inspections i. Failure Finding ii. On - Condition Scheduled Preventive Maintenance Run to Failure Design Changes

RCM Applications

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RCM gaining grounds in the wake of

Diminishing maintenance funds Pressure for machines to stay on line due to high electricity demands Scarcity of skilled maintenance staff

Applications of RCM

Requirements for RCM

CBM and PdM tools and applications

Conclusions

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RCM programmes intend to provide the appropriate amount of maintenance at the right time to prevent forced outages while at the same time eliminating unnecessary maintenance

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RCM results in
Increase in Cost Effectiveness Machine Uptime

Greater Understanding of Level of Risk that organization is managing

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Features of RCM
May be labor intensive and time consuming to set up initially May require additional monitoring of quantities, like temperature and vibration etc to be effective. This would mean new monitoring equipment with its own PM or human monitoring with multiple inspections May result in a run to failure or deferred maintenance philosophy for some equipment.

Reliability Centered Maintenance

Requirements of RCM
Monitoring equipment parameters such as temperatures, pressures, vibrations, leakage current, dissolved gas analysis etc

Testing on periodic basis and/ or when problems are suspected such as Doble testing, vibration testing and infrared scanning

Reliability Centered Maintenance Requirements of RCM (cont.)

Monitoring carefully the operator-gathered data Using intelligent Assets Management Systems which would reduce overall cost by focusing only on equipment that really needs attention

Reliability Centered Maintenance

CONCLUSIONS Most practical approach for RCM is always a combination of CBM and PM,

Monitoring, testing and using historical data as well as PM schedules to guide when equipment should be maintained

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