module 3 unit i " copyright 2002, information spectrum, inc. all rights reserved."...
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Module 3Module 3
UNIT IUNIT I
"Copyright 2002, Information Spectrum, Inc. All Rights Reserved."
INTRODUCTION TO RCMINTRODUCTION TO RCMINTRODUCTION TO RCMINTRODUCTION TO RCM
RCM TERMINOLOGY AND RCM TERMINOLOGY AND CONCEPTSCONCEPTS
RCM TERMINOLOGY AND RCM TERMINOLOGY AND CONCEPTSCONCEPTS
IntroductioIntroductionn
IntroductioIntroductionn
Module Preview:Module Preview:Module Preview:Module Preview:
FailuresFailures
IntroductionIntroduction
SeveritySeverity
Probability of FailureProbability of Failure
ReliabilityReliability
Types of MaintenanceTypes of Maintenance
Review and SummaryReview and Summary
CriticalityCriticality
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Module Module Objective:Objective:Module Module
Objective:Objective:
This module will introduce basic This module will introduce basic concepts and terminology used in concepts and terminology used in the RCM process.the RCM process.
IntroductioIntroductionn
IntroductioIntroductionn
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Module Module Objective:Objective:Module Module
Objective:Objective:IntroductioIntroductio
nnIntroductioIntroductio
nn
1. Define Failure Terminology:1. Define Failure Terminology:
Functional FailureFunctional Failure
Potential FailurePotential Failure
Failure ModeFailure Mode
2. Introduce the concepts of 2. Introduce the concepts of SeveritySeverity, , Probability of FailureProbability of Failure, and , and CriticalityCriticality and how they are related. and how they are related.
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Module Objective:Module Objective:Module Objective:Module Objective: IntroductioIntroductionn
IntroductioIntroductionn
3. Introduce the concept of 3. Introduce the concept of ReliabilityReliability..
4. Define the following maintenance terms:4. Define the following maintenance terms:
- Scheduled Maintenance - Unscheduled Maintenance - Scheduled Maintenance - Unscheduled Maintenance
- Preventive Maintenance - Corrective Maintenance - Preventive Maintenance - Corrective Maintenance
- Proactive Maintenance - Proactive Maintenance - Reactive Maintenance - Reactive Maintenance
- Condition Monitoring- Condition Monitoring - Condition Based Maintenance - Condition Based Maintenance
- Conditional Maintenance- Conditional Maintenance
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
FAILURESFAILURESFAILURESFAILURES
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
FailureFailureFailureFailureDefinitions:Definitions:Definitions:Definitions:
1.1. FAILURE FAILURE:: An identifiable deviation from a An identifiable deviation from a specified condition that is unsatisfactory to an specified condition that is unsatisfactory to an asset owner or manager.asset owner or manager.
RCM recognizes two types of failures:RCM recognizes two types of failures:
FUNCTIONAL FAILURE -FUNCTIONAL FAILURE - Inability of item Inability of item to perform a specific function within to perform a specific function within specified performance limitsspecified performance limits
POTENTIAL FAILURE –POTENTIAL FAILURE – DefinableDefinable and and detectable condition that indicates a detectable condition that indicates a functional failure will occurfunctional failure will occur
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
FailureFailureFailureFailureDefinitions:Definitions:Definitions:Definitions:
2.2. FAILURE MODE FAILURE MODE -- A specific physical A specific physical condition that causes a particular condition that causes a particular functional failurefunctional failure
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
SEVERITYSEVERITYSEVERITYSEVERITY
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
SeveritySeveritySeveritySeverityDefinition:Definition:Definition:Definition:
SEVERITYSEVERITY - - A category assigned to a A category assigned to a failure mode based on the impacts of failure mode based on the impacts of its potential effectsits potential effects
… … qualitative measures used to qualitative measures used to categorize the potential effects of categorize the potential effects of failures.failures.
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
CATEGORY I (CATASTROPHIC)CATEGORY I (CATASTROPHIC) Death or Permanent disability Death or Permanent disability Destruction of system/equipmentDestruction of system/equipment Significant breach of environmental Significant breach of environmental regulation regulation Damage > $1MDamage > $1M
CATEGORY III (MARGINAL)CATEGORY III (MARGINAL) Damage >$10K and < $100KDamage >$10K and < $100K Degraded ability to perform critical missionDegraded ability to perform critical mission Interrupted operationsInterrupted operations
CATEGORY II (CRITICAL)CATEGORY II (CRITICAL) Personal InjuryPersonal Injury Inability to perform primary missionInability to perform primary mission Damage >$100K and < $1MDamage >$100K and < $1M
CATEGORY IV (MINOR)CATEGORY IV (MINOR) Unscheduled maintenance or repairUnscheduled maintenance or repair Damage <$10K Damage <$10K
Example:Example:Example:Example: SeveritySeveritySeveritySeverity
Severity ClassificationsSeverity Classifications Aircraft Example Aircraft Example
Note: In some circumstances when an item performs a critical function and no Note: In some circumstances when an item performs a critical function and no effective back-up is available, loss of function for a defined period of time could be effective back-up is available, loss of function for a defined period of time could be considered critical or catastrophic. These conditions should be added to the severity considered critical or catastrophic. These conditions should be added to the severity
classifications as appropriateclassifications as appropriate
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
CATEGORY I (CATASTROPHIC)CATEGORY I (CATASTROPHIC) Death or Severe InjuryDeath or Severe Injury Significant Environmental Impact Significant Environmental Impact Loss of availability > 1 week Loss of availability > 1 week Damage > $1MDamage > $1M
CATEGORY III (MARGINAL)CATEGORY III (MARGINAL) Loss of availability > 4 hrs and < 24 hrsLoss of availability > 4 hrs and < 24 hrs Damage >$10K and < $100KDamage >$10K and < $100K
CATEGORY II (CRITICAL)CATEGORY II (CRITICAL) Minor InjuryMinor Injury Loss of availability > 24 hrs and < 7 daysLoss of availability > 24 hrs and < 7 days Damage >$100K and < $1MDamage >$100K and < $1M
CATEGORY IV (MINOR)CATEGORY IV (MINOR) Loss of availability < 4 hrsLoss of availability < 4 hrs Damage <$10K Damage <$10K
Example:Example:Example:Example: SeveritySeveritySeveritySeverity
Severity ClassificationsSeverity Classifications Plant Equipment Plant Equipment Example Example
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
PROBABILITY OF PROBABILITY OF FAILUREFAILURE
PROBABILITY OF PROBABILITY OF FAILUREFAILURE
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Probability of FailureProbability of FailureDefinition:Definition:Definition:Definition:
1.1. Probability of failureProbability of failure : : The probability that a The probability that a given failure mode will occur during a defined period.given failure mode will occur during a defined period.
2.2. Acceptable Probability of Failure (PAcceptable Probability of Failure (Paccacc):): The probability of a given failure mode occurring during a defined The probability of a given failure mode occurring during a defined period that is acceptable to a program or asset manager. period that is acceptable to a program or asset manager.
• The more severe the consequences, the lower The more severe the consequences, the lower PPacc acc should beshould be
• Values may be defined by regulatory Values may be defined by regulatory organizations or self imposed (by a program or organizations or self imposed (by a program or asset manager) asset manager)
• Values should be documented prior to analysisValues should be documented prior to analysis
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Probability of FailureProbability of FailureProbability of FailureProbability of FailureDefinition:Definition:Definition:Definition:
3.3. Actual Probability of Failure Actual Probability of Failure (P(Pactact)): : The The predicted or demonstrated probability of a given failure mode predicted or demonstrated probability of a given failure mode occurring during a defined period in the operating environment.occurring during a defined period in the operating environment.
PPactact can be measured from in-service data or can be measured from in-service data or
estimated from statistical failure distributionsestimated from statistical failure distributions
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
CRITICALITYCRITICALITYCRITICALITYCRITICALITY
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
CRITICALITY -CRITICALITY - A prioritization of the A prioritization of the combination of failure severity and failure combination of failure severity and failure frequency (or probability)frequency (or probability)
•Sometimes referred to as Sometimes referred to as RiskRisk
•Criticality may beCriticality may be documented documented qualitatively or quantitativelyqualitatively or quantitatively (Ref: MIL-(Ref: MIL-STD-1629)STD-1629)
•Asset managers/Programs may define Asset managers/Programs may define acceptable criticality limitsacceptable criticality limits by use of a by use of a Hazard Risk Matrix. (Qualitative Method)Hazard Risk Matrix. (Qualitative Method)
•Criticality can be used to set priorities Criticality can be used to set priorities for analysis or define acceptable riskfor analysis or define acceptable risk
CriticalityCriticalityCriticalityCriticalityDefinition:Definition:Definition:Definition:
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Hazard Risk Matrix:Hazard Risk Matrix:Hazard Risk Matrix:Hazard Risk Matrix:
FREQUENCYFREQUENCY
SEVERITYSEVERITY
FREQUENTFREQUENT (A)(A)
>> 1 per 1,000 1 per 1,000 HoursHours
PROBABLEPROBABLE (B) (B)
>> 1 per 10,000 1 per 10,000HoursHours
OCCASIONALOCCASIONAL (C) (C)
>> 1 per 100,000 1 per 100,000HoursHours
REMOTE REMOTE (D)(D)
>> 1 per 1,000,000 1 per 1,000,000HoursHours
IMPROBABLEIMPROBABLE (E) (E)
<< 1 per 1,000,000 1 per 1,000,000HoursHours
CATASTROPHIC (I)CATASTROPHIC (I)
CRITICAL (II)CRITICAL (II)
MARGINAL (III)MARGINAL (III)
MINOR (IV)MINOR (IV)
• Death or Permanent disabilityDeath or Permanent disability• Significant Environmental breach Significant Environmental breach • Damage > $1M, Downtime>2 daysDamage > $1M, Downtime>2 days• Destruction of system/equipmentDestruction of system/equipment
• Personal InjuryPersonal Injury• Damage >$100K and < $1MDamage >$100K and < $1M• Loss of availability > 24 hrs and Loss of availability > 24 hrs and < 7 days< 7 days
• Damage >$10K and < $100KDamage >$10K and < $100K• Loss of availability > 4 hrs andLoss of availability > 4 hrs and < 24 hrs< 24 hrs
• Damage <$10K Damage <$10K • Loss of availability < 4 hrsLoss of availability < 4 hrs
11HIGHHIGH
33HIGHHIGH
44HIGHHIGH
22HIGHHIGH
55HIGHHIGH
88MEDMED
66MEDMED
77MEDMED
99MEDMED
1010LOWLOW
1212ACCEPTACCEPT
1313ACCEPTACCEPT
1515ACCEPTACCEPT
1616ACCEPTACCEPT
1717ACCEPTACCEPT
2020ACCEPT
1919ACCEPT
1414ACCEPT
1111LOWLOW
1818ACCEPTACCEPT
CriticalityCriticalityCriticalityCriticality
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
RELIABILITYRELIABILITYRELIABILITYRELIABILITY
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
ReliabilityReliabilityReliabilityReliability
RELIABILITY -RELIABILITY - Probability that an Probability that an asset will perform its intended asset will perform its intended function for a specified period of function for a specified period of time under specified operating time under specified operating conditionsconditions
Actual Reliability is a function of the asset’s Actual Reliability is a function of the asset’s design, manufacturing process, usage profile, design, manufacturing process, usage profile, operating environment, and maintenance operating environment, and maintenance program.program.
Definitions:Definitions:Definitions:Definitions:
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
MAINTENANCE MAINTENANCE TERMSTERMS
MAINTENANCE MAINTENANCE TERMSTERMS
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition:
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE – actions – actions performed periodically (or performed periodically (or continuously) prior to functional failure continuously) prior to functional failure (or multiple failure/demand (or multiple failure/demand requirements for hidden failures) to requirements for hidden failures) to achieve the desired level of safety and achieve the desired level of safety and reliability for an itemreliability for an item
… … These actions are performed to prevent or These actions are performed to prevent or reduce consequences of failures.reduce consequences of failures.
Due to differences in the way the term Due to differences in the way the term Scheduled MaintenanceScheduled Maintenance is used, this course will is used, this course will attempt to use the term attempt to use the term Preventive MaintenancePreventive Maintenance only only
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinitionDefinitionDefinitionDefinition
• PROACTIVE MAINTENANCE PROACTIVE MAINTENANCE – any – any tasks used to predict or prevent tasks used to predict or prevent equipment failures.equipment failures.
Similar to Similar to Preventive MaintenancePreventive Maintenance except that it except that it generally excludes failure finding type tasks. generally excludes failure finding type tasks. Again, definitions may vary…Again, definitions may vary…
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition:
• CORRECTIVE MAINTENANCE CORRECTIVE MAINTENANCE –– repairs repairs or other corrective action taken or other corrective action taken after a failure has occurredafter a failure has occurred
For the purposes of this course, the term For the purposes of this course, the term Unscheduled Unscheduled MaintenanceMaintenance is synonymous with is synonymous with Corrective MaintenanceCorrective Maintenanceand and Reactive MaintenanceReactive Maintenance
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition:
• CONDITION MONITORING – CONDITION MONITORING – The use The use of specialized equipment to measure of specialized equipment to measure the condition of equipment.the condition of equipment.
Vibration Analysis, Oil Analysis, and ThermographyVibration Analysis, Oil Analysis, and Thermographyare examples of are examples of Condition MonitoringCondition Monitoring techniques techniques
Predictive Maintenance (PdM) and Prognosis and Health Predictive Maintenance (PdM) and Prognosis and Health Management (PHM) are usually interchangeable with Management (PHM) are usually interchangeable with Condition Monitoring.Condition Monitoring.
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition:
• Condition Based Maintenance Condition Based Maintenance – An – An equipment maintenance strategy equipment maintenance strategy based on measuring the condition of based on measuring the condition of equipment in order to assess equipment in order to assess whether it will fail during some whether it will fail during some future period, and then taking future period, and then taking appropriate action to avoid the appropriate action to avoid the consequences of that failure.consequences of that failure.
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceDefinition:Definition:Definition:Definition:
• Conditional or Opportunity Maintenance Conditional or Opportunity Maintenance –– Maintenance actions conducted as result Maintenance actions conducted as result of a specific condition, or as a result of of a specific condition, or as a result of specific circumstances or events. specific circumstances or events.
Examples of Conditional InspectionsExamples of Conditional Inspections• Hard LandingHard Landing• Unscheduled disassembly Unscheduled disassembly • Power InterruptionPower Interruption• Over/Under VoltageOver/Under Voltage• Lightning strikeLightning strike• Over stressOver stress• Unscheduled or scheduled shut-Unscheduled or scheduled shut-downdown
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Proactive MaintenanceProactive Maintenance
Preventive Maintenance (PM)Preventive Maintenance (PM)
Unscheduled MaintenanceUnscheduled Maintenance
Corrective Maintenance (CM)Corrective Maintenance (CM)
Reactive MaintenanceReactive Maintenance
Condition Based Maintenance Condition Based Maintenance Condition MonitoringCondition MonitoringPredictive Maintenance Predictive Maintenance Prognosis Health Management (PHM)Prognosis Health Management (PHM)Potential failuresPotential failures
Repairs or corrective actionsRepairs or corrective actionsRun to failureRun to failureFailure has occurredFailure has occurred
Preserves required functionalityReduces unplanned downtime
Requires investment
Fixes failures in unplanned mannerDowntime unpredictable
Addresses only “what’s broken”
RCM determines proper balance of planned and unplanned maintenance,RCM determines proper balance of planned and unplanned maintenance, along with “Other Actions”, to establish a “Failure Management Strategy”along with “Other Actions”, to establish a “Failure Management Strategy”
Scheduled MaintenanceScheduled Maintenance
Types of MaintenanceTypes of MaintenanceTypes of MaintenanceTypes of MaintenanceSummary:Summary:Summary:Summary:
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS
Review and Review and SummarySummary
Review and Review and SummarySummary
IntroductionIntroduction IntroductionIntroduction
RCM Terms & RCM Terms & ConceptsConceptsRCM Terms & RCM Terms & ConceptsConcepts
– Learning ObjectivesLearning Objectives
– FailuresFailures– Severity Severity – Probability of FailureProbability of Failure– CriticalityCriticality– ReliabilityReliability– Maintenance TermsMaintenance Terms
Module ObjectiveModule Objective Module ObjectiveModule Objective
– Introduce the primary Introduce the primary terminology and basic concepts terminology and basic concepts used in RCMused in RCM
RCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTSRCM TERMINOLOGY AND CONCEPTS