Beginning the Successful CMS-Compliant Journey to Reliability

Jim Carrel, CRL

Welcome and Introduction

• US Navy veteran• Graduate of The College of Emporia• ISO 18436-2 Category III Vibration Analyst (ANSI) through The Vibration Institute• Certified Reliability Leader (Association of Asset Management Professionals) • More than 4 decades in Physical Asset Operations, Maintenance, & Management• Member ASHE, VI, AMP, and IAM• Speaker, Author, Sales Coach, and Evangelist for Reliability

• Married for 30 years• Two adult sons, a daughter-in-law, and a first grandchild on the way• Reading, Home Projects, Golf• Living my life’s dream

Initial Thoughts

• Set Goals (or KPIs) – Know where you are going and be able to defend your vision to internal detractors

• Start where you are and not where people say you ought to be

• Eat the elephant one bite at a time

• Don’t try it alone

• Win early and often

• Plan to report at scheduled intervals

Key Performance Indicators (KPIs)

• Asset Development

• Organization & Management

• Performance Management (Building Performance Indicators)

• Maintenance Efficiency

Where to Get Started

Tribal KnowledgeThe collective wisdom of the organization. It resides in the sum of all the knowledge, experience, and capabilities of the individuals.

Physical Asset InventoryElectrical, Mechanical, BioMed, Fire/Life Safety, Structural, Controls, Conveyance, MedGas, Lab, Grounds, Central Plant, etc.

Why Does Equipment Fail?The Weibull Distribution

Sources of Equipment Failures

Stan Nowlan & Howard Heap (1978)“…Without a precise definition of what condition represents a failure, there is no way to assess its consequences or to define the physical evidence for which to inspect.”

RCM ImplementationIdentify&CodeEquipment

AssessCriticality FMECA

OEMFMEA

Strategies

Planning&Preparation

4xy

CMMSImplementMeasure&Report

HIGHCRITICALITY

MEDIUMCRITICALITY

LOWCRITICALITY

Reliability-centered Maintenance

“…the widespread use of the word RCM has led to the emergence of a number of processes that differ significantly from the original and fail to achieve the goals of Nowlan and Heap. Some are counterproductive.”

RCM Methodology

Step 1 System selection and information collection (identify system boundaries)

HW Heater

NG

City Water

RCM Methodology

Step 1 System selection and information collection (identify system boundaries)

Step 2 System description and functional block diagram

HotWaterSystem

HotWaterTank

HotWaterValves

RCM Methodology

Step 1 System selection and information collection (identify system boundaries)

Step 2 System description and functional block diagram

Step 3 System functions and functional failures – Preserve functions

RCM Methodology

• Gas valve failure

• Pressure relief leaking

• Tank failure

• Loss of power

• Sediment Build-up

RCM Methodology

Step 1 System selection and information collection (identify system boundaries)

Step 2 System description and functional block diagram

Step 3 System functions and functional failures – Preserve functions

Step 4 Failure mode and effects analysis (FMEA) – Identify failure modes that can defeat the function

RCM Methodology

No. ComponentDescription

FailureMode FailureEffect(s) Symptoms Safeguards Actions/Recommendations

1 Tank Tankfailure(Crack)WaterTankDry

FloodinginGarage

Waterflowingfromgarageontodriveway

-- Replacetank

2 GasPilotValve SolenoidFailure Flamefailure ColdwaterGasflow

interruptedReplacegaspilotvalve

3 HotWaterFaucet LeakingWaterusageGasusage

Dripping -- Periodicallyreplaceseat

FMEAHouseholdHotWaterSupplySystem

RCM Methodology

Step 5 Logic (decision) tree analysis (LTA) – Prioritize function need via the failure modes (Criticality Assessment)

Assessing Asset Criticality

The 7 RCM Questions1 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?

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?

Applying the 7 RCM Questions

What is the functional performance requirement for a primary chilled water pump?

How does it fail to do that?

What may cause the failure?

What happens when it does fail?

What is the effect of the failure?

What can be done to prevent or predict the failure?

What if that doesn’t work?

RCM Methodology

Step 5 Logic (decision) tree analysis (LTA) – Prioritize function need via the failure modes (Criticality Assessment)

Step 6 Task selection – Select only appropriate and effective maintenance tasks (PM, PdM, etc.)

The Evolution of Operations & Maintenance

<1940’s

Reactive RCM

1990’s

Predictive

1980’s

AM/IoT

Today

Preventive

1960’s

The Evolution of Operations & Maintenance

Actions performed on a time- or machine-run-based schedule that protect, preclude, or mitigate degradation of component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level.

What Are Optimum PM Intervals?

“In order for preventive maintenance to be beneficial, the failure rate of the system must increase over time and the cost of the planned preventive maintenance must be less than the cost of the unplanned corrective maintenance.”

(Weibull.com)

The Evolution of Operations & Maintenance

Measurements that detect the onset of system or component degradation (lower functional state), thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability.

RCM Methodology

Step 5 Logic (decision) tree analysis (LTA) – Prioritize function need via the failure modes (Criticality Assessment)

Step 6 Task selection – Select only appropriate and effective maintenance tasks (PM, PdM, etc.)

Step 7 Task packaging – which will carry the recommended RCM tasks to the plant (CMMS & Change Mgmt.)

RCM Methodology

Step 5 Logic (decision) tree analysis (LTA) – Prioritize function need via the failure modes (Criticality Assessment)

Step 6 Task selection – Select only appropriate and effective maintenance tasks (PM, PdM, etc.)

Step 7 Task packaging – which will carry the recommended RCM tasks to the plant (CMMS & Change Mgmt.)

Step 8 Living RCM program – comprising the actions necessary to sustain, over time, the beneficial results of Step 1-8

Make a Difference

Systems

CMMS

BASControlBASWO

HumanInterface

Reliability-centered Maintenance

Reliability-centered maintenance is an engineering framework

that enables the definition of a complete maintenance

regimen. It regards maintenance as the means to maintain the

functions a user may require of machinery in a defined

operating context.