r cm brochure

7/23/2019 r Cm Brochure

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RCM Process

RCM Plan

Outcomes

★Time or Cycle-Based actions?

★Condition-Based actions?

★Run-to-Failure?

Spare Parts andMaterials

★Where is the best placeto hold inventory?

★What should the inventorylevel be?

Maintenance

Performance Optimization

★How?★

Why?★

Where?

★When?★What?★Who?

Proactive

★When should root failurecause analysis beperformed?

★What is the best feedback loop toimprove the design?

★Do standards need tobe developed?

RELIABILITY-CENTERED MAINTENANCE (RCM)

Is Your Plant Running Safely/Effi ciently?

Is Your Fleet “Fleet” Enough?

Are Your Maintenance Costs Too High?

ROOT CAUSE FAILURE ANALYSIS | RELIABILITY PROGRAM SUPPORT

L I F E C Y C L E C O

S T I N G | H I G H L Y A C C E

L E R A T E D S T R E S S T E S T P L A N N I N G | S T R E S S A N A L Y S I S | D E S I G N

O F E X P E R I M E N T S

F A UL TTREEANAL

Y S I S | REL I ABI L I TYPR

EDI CTI ON | F AI L URE

M ODEEF F E CT S AND C

RI TI CAL I TYANAL Y S I S | AL L O CATI ON

THERMAL ANALYSIS | KNOWLEDGE MANAGEMENT | VENDOR QUALIFICATION



What is Reliability-Centered Maintenance (RCM)? An analytical method based on Design for Reliability (DFR) and Design for Maintainability (DFM) Best Practices

to match your organization’s preventive maintenance capabilities to the design characteristics of your product or

system.

What Benets does RCM Provide?❯

❯ Identifies maintenance actions that will reduce the probability of catastrophic product/system failure

❯

❯ Identifies cost-effective maintenance actions

❯❯ Promotes an optimal mix of maintenance action types

❯

❯ Applicable to DoD, government, industry and commercial systems, products and processes

Design for Reliability (DFR)

C

Analysis

FMECA(Evident & Hidden Failures)

Failure Mode Informaon:

PoF

AnalysisHALT/HAST

ModeSurrogate

Data

Failure Rate/Life Data:

Field Data

Analysis

Test Data

Analysis

Weibull &

Trend Analysis

Surrogate

Data

Design for Maintainability (DFM)

Accessibility Testability

Human FactorsTimes-to-

Repair

Field Performance

InducedFailures

Number of Maintenance

Personnel

Total Maintenance Hours

Maintenance Work

Orders per Year

RCM Decision Analysis

RCM

Plan/Strategy

RCM Task

RCM Task

RCM Task

Opmized

Total Ownership Cost

Product/System

Requirements

RCM Strategies

Run to Failure Prevenve Predicve Proacve

Random failure paerns

Not subject to wear

Prevenve Maintenance-

induced failures

Root-cause failure

analysis

Age exploraon

Failure modes and

effects analysis

(FMEA)/Failure

modes, effects and

cricality analysis

(FMECA)

Subject to wearout

Consumable

replacement

Failure paern

known

Small items

Non-crical

Inconsequenal

Unlikely to fail

Redundant

Qquanterion.com

PoF = Physics-of-failureHALT = Highly Accelerated Life Test

HAST = Highly Accelerated Stress Test

FMECA = Failure Modes, Effects and Criticality Analysis



What Criteria is Used to Make RCM Decisions?❯

❯ Failure consequences determine priority (safety- or function-critical)

❯

❯ Selection of each preventive maintenance task is based on inherent failure patterns

❯❯ Scheduled maintenance is based on functional or safety consequences

❯❯ Product/system redesign for safety may be required

❯❯ Maintenance actions should be economically justifiable

Besides Safety Issues, What Other RCM Criteria WouldDrive a Potential Redesign Decision?Decision criteria include:

❯

❯ How critical is the impact of failure?

❯

❯ Is the failed item expendable or not?

❯

❯ How effective is redesign at solving the problem?

❯❯ Can Condition Monitoring help, and is it justifiable?

❯❯ What about design redundancy?

Is the item expendable?Can redesign solve the problem

permanently and cost-effecvely?

NO YES

Redesign

PROACTIVE MAINTENANCE

Is there an effecve PM task that

will minimize funconal failure?Is CM cost and priority jusfied?

Is design redundancy jusfied

by cost and priority ?

YES

YES

YES

YESYES

YES

NO

NO

NO

NO

NO

NO

Will a failure have a direct and adverse effect

on crical system or process funconality?

Is there a Condion Monitoring (CM) technology (e.g., vibraon tesng/sensing,

thermography) that will give sufficient warning (alert/alarm) of impending failure?

Accept risk of failure

RUN TO FAILURE

Install redundant units

PROACTIVE MAINTENANCE

Define PM Task and Schedule

PREVENTIVE MAINTENANCE

Define CM Task and Schedule

PREDICTIVE MAINTENANCE

Yes No

Yes NoYes No

Yes No

Yes No Yes No Yes No

Yes NoSafety Mission All Others

Evident Failures Hidden Failures

Hidden or

infrequent

functions

Class D

Other

regular

functions(economics)

Class C

Operating

capability

(economics)

Class B

Critical

Safety

Class A

Scheduled

maintenance is

desired if it iscost effective in

reducing

corrective

maintenance

Scheduled

maintenance is

desired if it is

effective in

reducingprobability or

operational

consequences to

an acceptable

level

Scheduled maintenance

is required and must be

able to reduce risk to an

acceptable level or item

must be redesigned

unless basic design

constraints require

acceptance of the

identi ed risk

Scheduled

maintenance is

required to

reduce risk of

multiple failures

or unavailability

of function to an

acceptable

level?

Function

Is occurrence of a

failure evident to operating

crew in performance of

normal duties?

1

Does the failure

cause a loss of function or

secondary damage that has

a direct and adverse effect

on operating safety?

Does failure

have a direct and

adverse effect on

operational

capability?

Is there an

effective and applicable

prevention task or combinationof tasks that will prevent

functional failures?

Is a scheduled

failure nding

task available

and justi ed?

Is there

an effective and

applicable preventive

maintenance task or

combination of tasks

that will prevent

functional

failures?

Is there an


preventive maintenance

task or combination of

tasks that will prevent


Is there an


preventive maintenance

task or combination of

tasks that will prevent


2

3

7

8

65

4

Describe and

classify work

Describe and

classify task(s)

Submit a

safety related

design change

Describe and

classify task(s)

No task

requiredDescribe and

classify task(s)

No task

required

Describe and

classify task(s)

Submit a safety

related design

change if appropriate

No task required

Submit a safety

related design

change if appropriate

quanterion.com



What Can Quanterion do to Help?❯

❯ Define product/system R&M requirements

❯

❯ Perform Design for Reliability RCM-related tasks

❯− PoF Analysis

❯− Define HALT/HAST and interpret results

❯− Collect/analyze failure mode distributions

❯− Collect/analyze surrogste data

❯−Perform FMEA/FMECA and root cause analysis

❯❯ Analyze and Assess Maintainability Design Attributes

❯❯ Define and implement an RCM Decision Analysis Plan/Strategy

❯− Significant function selection

❯− RCM task evaluation selection & implementation

❯❯ Collect, analyze and assess RCM performance data

❯− Field and test failures, down to root cause

❯− Weibull & trend analysis

❯− Field maintenance data

❯❯ Optimize RCM performance (feedback loop)

Credentials As examples of our credentials in RMQ (as well as software engineering, cybersecurity, and knowledge management), we

are the day-to-day operator of the DoD’s Center of Excellence in these technologies:

❯

❯ Authors of over 80 publications, papers and presentations and software tools in R&M

❯❯ SMRP-certified engineers for direct RCM support

❯❯ ASQ CRE-Certified consulting engineers and instructors in Reliability training

❯❯ Development of joint government/industry R&M Standards and Handbooks

❯❯ Performed R&M assessments and analyses for numerous DoD, government, industrial and commercial

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n . c o

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❯❯❯ Requirements Analysis

❯❯❯ Metrics and Goal Setting

❯❯❯ System Modeling

❯❯

❯ Analysis of Alternatives

❯❯❯ Allocation

❯❯❯ Benchmarking

❯❯❯ Reliability Gap Analysis

❯❯❯ Reliability Program

Planning

❯❯❯ Reliability/Functional

Block Diagrams

❯❯❯ Reliability Prediction

❯❯

❯ Reliability Growth Modeling❯❯❯ FMEA/FMECA

❯❯❯ Fault Tree Analysis

❯❯❯ Risk and Safety Analysis

❯❯❯ Component and

Materials Selection

❯❯❯ Stress Analysis and Derating

❯❯❯ Vendor Selection

❯❯❯ Life Cycle Costing

❯❯❯ Warranty and Sparing

Analyses

❯❯❯ Design of Experiments

❯❯❯ Reliability Centered

Maintenance

❯❯❯ Reliability Test Plan

Development

❯❯❯ Highly Accelerated Life

Test (HALT) Planning

❯❯❯ Environmental Testing

❯❯❯ Stress Test Planning

❯❯❯ Reliability Demonstration

❯❯❯ Failure Analysis & Corrective

Action System (FRACAS)

❯❯❯ Vendor Reliability

Auditing/Assessment

❯❯❯ Product Qualification

❯❯❯ Highly Accelerated

Stress Screening

❯❯❯ Environmental

Stress Screening

❯❯❯ Vendor Qualification

❯❯❯ Warranty Analysis

❯❯❯ Hazard Rate/Risk Analysis

❯❯❯ Logistics (Depot)

Assessment

❯❯❯ Field Reliability Assessment

❯❯❯ Data Collection/Analysis

❯❯❯ Lifetime Extension

ServicesWe provide professional high-quality services in all aspects of RMQ, offering an independent unbiased perspective. We

are happy to enter into Nondisclosure Agreements and have a variety of easy-to-use contracting arrangements.

http://thecsiac.com

Reliability Information Analysis Center

http://theRIAC.org

RCM-Related Documents

❯❯❯ Maintenance Steering

Group (MSG-3)

❯❯❯ NAVAIR 0D-25-403. “Guidelines for

the Naval Aviation RCM Process”

❯❯

❯ Army Pamphlet 750-40, “Guideto RCM for Fielded Equiptment”

❯❯❯ MIL-STD-3034, “RCM Process”

❯❯❯ Society of Automotive

Engineers (SAE)

❯− SAE JA 1011, “Evaluation

Criteria for RCM

Processes”

❯− SAE JA 1012, “A Guide to

the RCM Standard”