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UNIT IIUNIT II
RCM PROCESSRCM PROCESSRCM PROCESSRCM PROCESS
Module 2Module 2
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
"Copyright 2002, Information Spectrum, Inc. All Rights Reserved."
IntroductioIntroductionn
IntroductioIntroductionn
• IntroductionIntroduction• IntroductionIntroduction
• RCM Planning and PreparationsRCM Planning and Preparations• RCM Planning and PreparationsRCM Planning and Preparations
• Review and SummaryReview and Summary• Review and SummaryReview and Summary
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Module Preview:Module Preview:Module Preview:Module Preview:
Module Objective:Module Objective:Module Objective:Module Objective: IntroductioIntroductionn
IntroductioIntroductionn
This module provides an overview of This module provides an overview of the elements that must be addressed the elements that must be addressed prior to beginning an RCM analysis prior to beginning an RCM analysis and how those issues affect the and how those issues affect the analysis. analysis.
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
1. Identify Team and responsibilities 4. Identify and document Review Process2. Identify analysis items 5. Orientation/Training3. Prioritize Items 6. Ground Rules and Assumptions
PLANNING AND PREPARATION
ANALYSIS
RCM ProcessRCM ProcessRCM ProcessRCM Process
AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan
AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan
MaintenanceMaintenanceRequirementsRequirements
MaintenanceMaintenanceRequirementsRequirements
Maintenance Maintenance ProgramProgram
Maintenance Maintenance ProgramProgram
DataDataDataData
1. Equipment Kick-off Meeting2. Initial Data Gathering3. Hardware Partition4. Function5. Functional Failure6. Failure Mode7. Failure Effects8. Failure Consequences9. Task Evaluation10. Task Selection
1. Package Maintenance Task2. Implement Other Actions
SAE JA-
1011
ResultsResults
IMPLEMENT RESULTS
1. Emergent Issues2. Age Exploration3. Hardware Changes4. Trend/degrader analysis5. Document Reviews
SUSTAIN
FMECA
Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
1.1. Identify the RCM Team and Identify the RCM Team and responsibilitiesresponsibilities
2.2. Identify the Items subject to AnalysisIdentify the Items subject to Analysis
3.3. Prioritize Analysis ItemsPrioritize Analysis Items
4.4. Identify and document the analysis Identify and document the analysis review and approval processreview and approval process
5.5. Project Orientation Brief/TrainingProject Orientation Brief/Training
6.6. Develop Analysis Ground Rules & Develop Analysis Ground Rules & AssumptionsAssumptions
Steps:Steps:Steps:Steps: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Step 1: Identify the RCM Team and responsibilitiesStep 1: Identify the RCM Team and responsibilities• Team compositionTeam composition
OperatorsOperators MaintainersMaintainers Engineering/Logistics/Safety/SMEEngineering/Logistics/Safety/SME Data Managers/AnalystsData Managers/Analysts RCM Analysts (may be one or more of above or RCM Analysts (may be one or more of above or
separate)separate) Project Manager/RCM Implementation Project Manager/RCM Implementation
Manager/Facilitator (one of above or separate)Manager/Facilitator (one of above or separate)• ResponsibilitiesResponsibilities
Support roles (subject matter expertise)Support roles (subject matter expertise) Analysis and documentationAnalysis and documentation Data collection Data collection Review and approvalReview and approval Implementation Implementation
• Team Availability and InterfaceTeam Availability and Interface• Analysis structure (facilitated group or assigned Analysis structure (facilitated group or assigned
analyst)analyst)
Step1:Step1:Step1:Step1: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Step 2: Identify Analysis ItemsStep 2: Identify Analysis Items• List the upper level item or items that will be analyzedList the upper level item or items that will be analyzed• May be an entire asset or a list of equipment/systemsMay be an entire asset or a list of equipment/systems• Include boundaries if necessaryInclude boundaries if necessary• Be specific Be specific
Examples of analysis items:Examples of analysis items:• E-6 aircraftE-6 aircraft• Sea-wolf SubmarineSea-wolf Submarine• Plant water supply System (including well, pumps, Plant water supply System (including well, pumps,
and piping up to main shut-off valve)and piping up to main shut-off valve)• Water-jet cutting machine and Milling MachineWater-jet cutting machine and Milling Machine• Soot Blowing System, Absorber Tower System, and Soot Blowing System, Absorber Tower System, and
Boiler Air and Gas System Boiler Air and Gas System
Step 2:Step 2:Step 2:Step 2: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Step 3: Prioritize Analysis Items (Analysis scope)Step 3: Prioritize Analysis Items (Analysis scope) List the preferred order that upper level assets List the preferred order that upper level assets
will undergo analysiswill undergo analysis Does not mean one item must be completed Does not mean one item must be completed
before another startsbefore another starts In the case of complex items such as an entire In the case of complex items such as an entire
aircraft or major system, additional prioritization aircraft or major system, additional prioritization may be needed after hardware partitioningmay be needed after hardware partitioning
Step 3:Step 3:Step 3:Step 3: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Step 4: Identify and Document the Review and Step 4: Identify and Document the Review and Approval Process Approval Process
• Who is responsible for review and approval of Who is responsible for review and approval of each analysiseach analysis
• Are reviews informal or formal, group or Are reviews informal or formal, group or individualindividual
• Review/Approval should include senior RCM Review/Approval should include senior RCM analyst and system subject matter expertanalyst and system subject matter expert
Step 4:Step 4:Step 4:Step 4: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Step 5: Project Orientation Brief/TrainingStep 5: Project Orientation Brief/Training• Objective is to begin the “buy-in” process and Objective is to begin the “buy-in” process and
remove potential roadblocksremove potential roadblocks• Should include all personnel significantly Should include all personnel significantly
affected by RCM results, including operations affected by RCM results, including operations and management representativesand management representatives
• Should include the following topics:Should include the following topics: Items in step 1-4Items in step 1-4 General RCM process overviewGeneral RCM process overview What’s in it for everyoneWhat’s in it for everyone What’s expected of everyoneWhat’s expected of everyone Statement of management buy-inStatement of management buy-in Statement of key groups (maintenance, Statement of key groups (maintenance,
production) buy-in. (team member advocates)production) buy-in. (team member advocates)• Formal analyst training only required for key Formal analyst training only required for key
participantsparticipants
Step 5:Step 5:Step 5:Step 5: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Step 6: Ground Rules & Assumptions (GR&A)Step 6: Ground Rules & Assumptions (GR&A)• A compilation of information required by RCM A compilation of information required by RCM
analysts to perform analysisanalysts to perform analysis• Items included:Items included:
- Description of operating environment (operating Description of operating environment (operating context) context)
- Standard operating proceduresStandard operating procedures- Data sourcesData sources- Failure mode sourcesFailure mode sources- Analytical methodsAnalytical methods- Cost-benefit analysis methodsCost-benefit analysis methods- Default ValuesDefault Values- Acceptable probability of failureAcceptable probability of failure- Labor ratesLabor rates- Equipment usage ratesEquipment usage rates
Step 6:Step 6:Step 6:Step 6: Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
RCM Program RCM Program PlanPlan
RCM Program RCM Program PlanPlan
Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
RCM Projects should document the results of the RCM Projects should document the results of the planning and preparation steps into an planning and preparation steps into an RCM RCM Program PlanProgram Plan
• Scope and size of plan is dependent on Scope and size of plan is dependent on projectproject
• Ensures consistency of analysis processEnsures consistency of analysis process• Establishes priorities and scheduleEstablishes priorities and schedule• Documents contributions of team Documents contributions of team
members and concurrence by members and concurrence by management management
• Can be used for funding justification and Can be used for funding justification and to gain management supportto gain management support
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
RCM Program PlanRCM Program PlanRCM Program PlanRCM Program Plan Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
RCM Program Plan Elements:RCM Program Plan Elements:• Team and Responsibilities (Planning Step 1)Team and Responsibilities (Planning Step 1)• Analysis scope (what and what order: Planning Analysis scope (what and what order: Planning
steps 2 and 3)steps 2 and 3)• Review and approval process (Planning Step 4)Review and approval process (Planning Step 4)• Training Requirements (Planning Step 5 +)Training Requirements (Planning Step 5 +)• Ground Rules and Assumptions (Planning Step Ground Rules and Assumptions (Planning Step
6)6)• Sustaining task proceduresSustaining task procedures• Hazard Risk MatrixHazard Risk Matrix• Metrics and Reporting requirementsMetrics and Reporting requirements• Funding requirementsFunding requirements• Plan of action and milestones Plan of action and milestones • Contractor support requirementsContractor support requirements• DeliverablesDeliverables
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Team and Team and ResponsibilitiesResponsibilities
Team and Team and ResponsibilitiesResponsibilities
Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
Facilitated approach vs. dedicated Facilitated approach vs. dedicated analystanalyst• Facilitated group approachFacilitated group approach
• Analysis is performed during meetings of key Analysis is performed during meetings of key personnel in presence of a facilitatorpersonnel in presence of a facilitator
• Maximizes buy-in from participantsMaximizes buy-in from participants
• Limited by amount of time key persons can Limited by amount of time key persons can attend meetingsattend meetings
• Focuses on consensus of stakeholders vice Focuses on consensus of stakeholders vice detailed/analytical solutions detailed/analytical solutions
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Team and Team and ResponsibilitiesResponsibilities
Team and Team and ResponsibilitiesResponsibilities
Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
Facilitated approach vs. dedicated Facilitated approach vs. dedicated analystanalyst•Dedicated analystDedicated analyst
• Analysis is performed by dedicated RCM Analysis is performed by dedicated RCM expert(s) using information gathered from expert(s) using information gathered from system experts and other sourcessystem experts and other sources
• Still must include participation of key SMEs Still must include participation of key SMEs (operators/maintainers) for analysis to be (operators/maintainers) for analysis to be effectiveeffective
• Less daily impact on non-RCM analyst Less daily impact on non-RCM analyst participantsparticipants
• Participants don’t need extensive RCM training, Participants don’t need extensive RCM training, just basic orientationjust basic orientation
• More conducive to outside analytical assistance More conducive to outside analytical assistance (outsourcing)(outsourcing)
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Team and Team and ResponsibilitiesResponsibilities
Team and Team and ResponsibilitiesResponsibilities
Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
Facilitated approach vs. dedicated analystFacilitated approach vs. dedicated analyst
Which is best? Which is best?
Depends on desires and resources of each Depends on desires and resources of each organizationorganization
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Scope of Scope of Analysis:Analysis:Scope of Scope of Analysis:Analysis:
Planning and Planning and PrepPrep
Planning and Planning and PrepPrepScope May be dependent on:Scope May be dependent on:
• Funding/personnel resources/management Funding/personnel resources/management commitmentcommitment• Pilot project vs. full-scalePilot project vs. full-scale
•Objectives of analysisObjectives of analysis• Fix current “headaches” vs. maintenance optimizationFix current “headaches” vs. maintenance optimization
• ““Age/Remaining planned Life” of analysis items Age/Remaining planned Life” of analysis items • Potential risk vs. returnPotential risk vs. return
• Criticality analysis (Risk Indices) may be used Criticality analysis (Risk Indices) may be used to further prioritize or limit the analysisto further prioritize or limit the analysis
MUST ensure potential safety/environmental MUST ensure potential safety/environmental issuesissues
are not overlooked in less than complete are not overlooked in less than complete analysis!analysis!
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
RCM TrainingRCM TrainingRCM TrainingRCM Training Planning and Planning and PrepPrep
Planning and Planning and PrepPrepTraining Requirements (Planning Step 5 +)Training Requirements (Planning Step 5 +)
•OrientationOrientation• Provided to significantly affected parties and Provided to significantly affected parties and
participants early in the processparticipants early in the process• Essential in the dedicated analyst approachEssential in the dedicated analyst approach• Typically 2 – 4 hoursTypically 2 – 4 hours
• Analyst training Analyst training •Analyst approach: only required for those key Analyst approach: only required for those key
individuals intimately involved in the analysis individuals intimately involved in the analysis processprocess
• Facilitated approach: typically provided to all Facilitated approach: typically provided to all participantsparticipants
• Typically 3-5 daysTypically 3-5 days
•Management overviewManagement overview• Provided to key management to gain buy-in Provided to key management to gain buy-in
develop agreement on expectationsdevelop agreement on expectations• Typically 1-4 hoursTypically 1-4 hours
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Sustaining the RCM Sustaining the RCM Analysis:Analysis:
Sustaining the RCM Sustaining the RCM Analysis:Analysis:
• Defines how the RCM team plans to monitor Defines how the RCM team plans to monitor and improve the effectiveness of the and improve the effectiveness of the maintenance program throughout the life of maintenance program throughout the life of the equipmentthe equipment
• RCM must be maintained over time to realize RCM must be maintained over time to realize its full benefitits full benefit
RCM Sustainment is discussed in more detail in Unit IVRCM Sustainment is discussed in more detail in Unit IV
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
Planning and Planning and PrepPrep
Planning and Planning and PrepPrep
Review and Review and SummarySummary
Review and Review and SummarySummary
IntroductionIntroduction
– Learning ObjectivesLearning Objectives
Planning and preparationPlanning and preparation
– Required StepsRequired Steps
– RCM PlanRCM Plan
– Provide an overview of the issuesProvide an overview of the issues that must be accomplished prior tothat must be accomplished prior to beginning RCM analysis.beginning RCM analysis.
Module ObjectiveModule Objective
PLANNING AND PLANNING AND PREPARATIONPREPARATION
PLANNING AND PLANNING AND PREPARATIONPREPARATION
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