Reliability Centered Maintenance (RCM)

Introduction to RCM
 A process used to determine what must be
done to ensure that any physical asset
continues to do what its user want it to do
in its present operating context.
 A tool to define suitable program to
maintain the asset function.
Application of RCM
To review the maintenance policy for any equipment.
This applies in particular to:
•New equipment if your are a designer or developer.
•Equipment for which the operating conditions are non-
standard.
•Equipment lacking documentation.
•“Reverse RCM(PMO)”, starting from existing plan or
manufacturers recommendations, to review activities.
•Develop data structure for analysis of failure modes,
maintenance workloads and resource requirements and for
creation of schedules.

Benefit of RCM
 Improved understanding of how machine works, its
capabilities and limitations.
 Understanding the reasons for maintenance, leading to
greater commitment to maintenance activities and to
equipment effectiveness.
 More cost-effective maintenance including pro-active
maintenance and condition monitoring.
 Improved safety and environmental protection.
Methodology

Maintenance
Failure
Task selection Program

Seven Basic Questions

 หนาที่อุปกรณ (Functions)?
 ความขัดของเชิงหนาที่ (Functional Failures)?
 รูปแบบความขัดของ (Failure Modes)?
 ผลกระทบจากความขัดของ (Failure Effects)?
 ผลสืบเนื่องจากความขัดของ (Failure Consequences)?
 การพยากรณ หรือ ปองกันความขัดของ(Proactive
Maintenance)?
 มีวิธีการอื่นอีกหรือไม ถาหากไมสามารถพยากรณหรือกําหนดการ
ปองกันที่เหมาะสมได (Maintenance action, if no proactive
maintenance)?
RCM Process Flow Chart

Failures Identification
 Failure Mode and Effect Analysis (FMEA)
 Functions
 Functional Failures
 Failure Modes
 Failure Effects
Functions
 Determine what its user want it to do
 Desired Standard (Performance Standard)

Functions
 However, every physical asset has more
than one-often several-functions. If the
objective of maintenance is to ensure that
the asset can continue to fulfill these
functions, then they must all be identified.
Primary and Secondary functions
 Primary functions can be defined as the
importance of the asset for plant.
 Secondary functions can be defined as the
requirements to maintain primary functions.

Secondary function
 To ensure that none of these functions are
overlooked, they are divided into seven
categories as follows:
 Environmental integrity
 Safety / structural integrity
 Control / containment / comfort
 Appearance
 Protection
 Economy / efficiency
 Superfluous functions
Functional Failures
 A state in which a physical asset or system
is unable to perform a specific function to a
desired level of performance.
SAE JA1011 Evaluation Criteria for RCM Process

 The inability of any asset to fulfill a function

to a standard of performance which is
acceptable to the user.

Functional Failures

 Acceptable and Unacceptable Condition.

Not at all
Upper limit Too Much

Performance Acceptable
Standard

Lower limit Too Little

Functional Failures
 Different views about failures.
 Oil leakage in a hydraulic system.

Production Safety
Maintainer officer
Manager

Functional Failures

Production Safety
Maintainer
Manager officer
Functions and Functional Failures

ระบบดังภาพประกอบด้วยอุปกรณ์ 3 X, ถั ง Y และ
Centrifugal pump
X ไปถัง Y ด้วยอัตราการ
800 liters/minute

Functions and Functional Failures

Centrifugal pump
รายละเอียดของ Centrifugal pump : ประกอบด้วย
Impeller, Motor, Bearing และ Gear box ใช้ Lube oil ใน
โดยมีระบบ Protection Trip
pump เมือ Lube oil temperature มีค่าเกินกว่า 90°C
Function & Functional Failure

Functional Failure :

Too much
สูบนํ ามา กกว่ า800 ลิตรต่อนาที

Primary Function Too Little

Action : เพือสู บนํ า (จากถั ง X ไปถั ง Y) สูบนํ าน้ อยกว่ า800 ลิตรต่อนาที
Performance Standard :
800 ลิตรต่อนาที Not at all
สูบนํ าไม่ ได้ เลย

Function & Functional Failure

Functional Failure :

Too much
อุณหภูมิของ Lube oil >90°C

Secondary Function
ขณะ pump ทํ างานอุณหภูมิของLube oil Too Little
< 90°C อุณหภูมิของ Lube oil <90°C
Function & Functional Failure

Functions Functional Failures

X ไปถัง Y ด้วย สูบนํ าไม่ ได้ เลย

อัตราการไหลไม่ต ํ ากว่ า 800 ลิตร
ต่อนาที โดยอุณหภูมิของ Lube สู บนํ า < 800 ลิตรต่อนาที
oil ไม่เกิน 90°C
อุณหภูมิของ Lube oil >90°C

Failure Mode
 Any event which causes a functional failures.
 The best way to show the connection and
the distinction between failed states and the
events which could cause them is to list
functional failures first, then to record the
failure modes which could cause each
functional failures.
 Do not try to list every single failure
possibility regardless of its likelihood.
Failure Mode

Functional Failures Failure Modes

สูบนํ าไม่ ได้ เลย Coupling แตกหักจากความล้ า

Strainer อุดตั นเนือง จากวั สด ุ แปลกปลอม

Motor winding short circuit เนือง จาก
Insulation เสือมสภา พ
Impeller ติดเนือง จากมี วั สด ุ แปลกปลอมเ ข้ าไปขั ด

Bearing แตก
ชุด Gear แตกหักจากความล้ า

Failure Mode

Functional Failures Failure Modes

สู บนํ า < 800 ลิตรต่อนาที Impeller สึ กหรอ

Strainer อุดตันบางส่ วนจากวั สดุแปลกปลอม

รัวเนือง จาก Seal เสือมสภา พ
Failure Modes
 What failure modes should be listed?

 Failure modes which have occurred before.

 Failure modes which are already the subject of
proactive maintenance routine.
 Any other failure modes which have not yet
occurred but which are considered to be real
possibilities.

Failure Effects
 Failure effects describe what happens
when a failure mode occurs
 what evidence (if any) that the failure
has occurred
 in what ways (if any) it poses a threat to
safety or the environment
 in what ways (if any) it affects
production or operations
 what physical damage (if any) is caused
by the failure
 what must be done to repair the failure.
Failure Effect

Failure Modes Failure Effects

Coupling แตกหักจากความล้า Operator สังเกตเห็น Alarm “Loss of

Flow” จึง Manual trip pump จากนั น
แจ้ งให้ Maintenance เข้ าไปเปลียน
Coupling ใช้เวลา 4 ชัวโมง จึ งแล้ วเ สร ็ จ

Failure Consequences

 The way(s) in which the effects of a failure

mode or a multiple failure matter
 Hidden
 Safety & Environment
 Operation
 Non-operation
Failure Consequences

 Hidden Consequences
 A failure modes whose effects do not become
apparent to the operating crew under normal
circumstances if the failure mode occurs on its
own.
 Protection system
 Redundant system
 Emergency system
 Instrument
 Etc.

Failure Consequences

 Safety & Environment Consequences

 A failure has safety consequences if it could hurt or
kill someone. It has environmental consequences if it
could lead to a breach of any corporate, regional or
national environmental standard
Failure Consequences

 Operational Consequences
 A failure has operational consequences if it
affects production or operations (output,
product quality, Customer service or
operating costs in addition to the direct cost
of repair).
 Non-operational Consequences
 Evident failures in this category affect neither
safety nor production, so they involve only
tile direct cost of repair.

Task Selection
Failure

Failure Consequence

Proactive Tasks

Default Action
 Task Selection
Failure

Safety or
Hidden Operation Non-operation
Environment

•On-condition Tasks
•Scheduled Restoration
•Scheduled Discard

Failure-finding Combination No Scheduled No Scheduled

Tasks Task Maintenance Maintenance
No Scheduled Redesign Redesign Redesign
Maintenance
Redesign

Proactive Task
 ON-CONDITION TASKS
 Any on-condition task (or predictive or condition-
based or condition monitoring task) that is selected
shall satisfy the following additional criteria:
 There shall exist a clearly defined potential failure.
 There shall exist an identifiable P-F interval (or failure
development period).
 The task interval shall be less than the shortest likely P-F
interval.
 The shortest time between the discovery of a potential
failure and the occurrence of the functional failure (the P-F
interval minus the task interval) shall be long enough for
predetermined action to be taken to avoid, eliminate, or
minimize the consequences of the failure mode.
Proactive Task
 P-F Interval

• It is possible to define a clear potential failure condition.

• The P-F interval is reasonably consistent.
• It is practical to monitor the item at intervals less than the P-F
interval.

Proactive Task

7%
D
Routine Overhauls are
a Waste of Time 14%
E

68%
F
Proactive Task
 SCHEDULED RESTORATION TASKS
 Any scheduled restoration task that is selected shall satisfy
the following additional criteria:
 There shall be a clearly defined (preferably a
demonstrable) age at which there is an increase in the
conditional probability of the failure mode under
consideration.
 A sufficiently large proportion of the occurrences of this
failure mode shall occur after this age to reduce the
probability of premature failure to a level that is tolerable
to the owner or user of the asset.
 The task shall restore the resistance to failure (condition)
of the component to a level that is tolerable to the owner
or user of the asset.

Proactive Task
 SCHEDULED DISCARD TASKS
 Any scheduled discard task that is selected shall satisfy the
following additional criteria:
 There shall be a clearly defined (preferably a demonstrable) age
at which there is an increase in the conditional probability of the
failure mode under consideration.
 A sufficiently large proportion of the occurrences of this failure
mode shall occur after this age to reduce the probability of
premature failure to a level that is tolerable to the owner or user
of the asset.
Proactive Task

4%
A
Routine Overhaul or
Replacement may be 2%
justified B

5%
C

Proactive Task
 MTBF
MTBF

F
a
I
l
u
r
e

F Constant Rate Useful Life

r
e
q
u
e
n
y
Time since last Failure
Proactive Task

 Scheduled Restoration / Discard

Repair or Replace
Fail

Fixed Period

Proactive Task

Optimum
Frequency

High probability
of Breakdown
Low probability Under Maintained
of Breakdown
Over Maintained
Default Action
 Failure Finding Task.
 Checking hidden functions to find out
whether they have failed.

Default Action
 Combination Task

Risk to safety
or environment
On-condition task

Repair / Replace
Default Action
 Redesign

Default Action
 Run-to-failure or No Schedule
Maintenance
 Decision Diagram

Information Worksheet
SYSTEM No. Facilitator Date. Sheet

RCM INFORMATON of
WORKSHEET
SUB-SYSTEM No. Auditor Date.

FAILURE MODE (Cause of FAILURE EFFECT (What happens

FUNCTION FUNCTIONAL FAILURE
failure) when it fails)
 Information Worksheet

Decision Worksheet
SYSTEM No. Facilitator Date. Sheet

RCM II DECISION
WORKSHEET SUB-SYSTEM No. Auditor Date. Page
of

Information Consequence H1 H2 H3
S1 S2 S3 Default tasks
Reference Evaluation
O1 O2 O3
Proposed Tasks Initial Interval Can be done by
N1 N2 N3
F FF FM H S E O H4 H5 S4
Decision Worksheet

H Y es
S
No
E
No
O

EVENT ? Safety? Environment? Operation?

No Y es Ye s Yes No
H1 S1 O1 N1
Detectable ? $ ? Detectable ? $ ? Detectable ? $ ? Detectable ? $ ?
Ye s Y es Y es Yes
CBM No
CBM No
CBM No
CBM No

H2 SR can reduce the S2 SR can reduce the 02 SR can reduce the N2 SR can reduce the
failure rate ? $ ? failure rate ? $ ? failure rate ? $ ? failure rate ? $ ?
Ye s Y es Y es Yes
SR No
SR No
SR No
SR No

H3 SD can reduce the S3 SD can reduce the 03 SD can reduce the N3 SD can reduce the
failure rate ? $ ? failure rate ? $ ? failure rate ? $ ? failure rate ? $ ?
Yes Yes Yes Y es
SD No
SD No
SD No
SD No

H4 Failure Finding S4
Combination ? $?
NSM NSM
Task ? $ ?

FFT Yes No
Combination
of tasks RD RD RD
Yes No
Safety? H5
Environment?

RD Yes No
NSM RD

Asset Ranking

Highly Critical
RCM
10 - 20 %
Critical

FMEA Mid Level Critical 20 - 30 %

Low Level Critical 45 - 50 %

Schedule

Run to Fail Non Critical 5 - 10 %