RELIABILITY-CENTERED

MAINTENANCE (RCM)
RCM IS A SYSTEMATIC
CONSIDERATION OF SYSTEM
FUNCTIONS, THE WAY FUNCTIONS
CAN FAIL, & A PRIORITY-BASED
CONSIDERATION OF SAFETY AND
ECONOMICS THAT IDENTIFIES
APPLICABLE & EFFECTIVE PM TASKS.
 RELIABILITY-CENTERED
MAINTENANCE (RCM)
RELIABILITY-CENTERED
MAINTENANCE (RCM) IS THE
PROCESS OF DETERMINING THE
MOST EFFECTIVE MAINTENANCE
APPROACH.
RCM WAS FIRST APPLIED ON A
LARGE SCALE TO DEVELOP THE
MAINTENANCE PROGRAM OF
THE BOEING 747. KNOWN AS
MSG-3 IN THE AEROSPACE
INDUSTRY.
 RELIABILITY-CENTERED
MAINTENANCE (RCM)
RCM IS A TECHNIQUE FOR DEVELOPING A
PM PROGRAM.
IT IS BASED ON THE ASSUMPTION THAT
THE INHERENT RELIABILITY OF THE
EQUIPMENT IS A FUNCTION OF THE
DESIGN AND THE BUILD IN QUALITY.
AN EFFECTIVE PM PROGRAM WILL ENSURE
THAT THE INHERENT RELIABILITY IS
REALISED.
MAIN OBJECTIVE OF RCM
TO REDUCE THE
MAINTENANCE COST, BY
FOCUSING ON THE MOST
IMPORTANT FUNCTIONS
OF THE SYSTEMS, AND
AVOIDING OR REMOVING
MAINTENANCE ACTIONS
THAT ARE NOT STRICTLY
NECESSARY.
 RCM HISTORY
ORIGINATED IN THE AIRLINE INDUSTRY IN
THE 1960’S.
BY THE LATE 1950’S, THE
COST OF MAINTENANCE ACTIVITIES IN THE
AIRLINE INDUSTRY HAD BECOME HIGH
ENOUGH TO WARRANT A SPECIAL
INVESTIGATION INTO THE EFFECTIVENESS
OF THOSE ACTIVITIES.
ACCORDINGLY, IN 1960, A TASK FORCE WAS
FORMED.
 RELIABILITY CENTERED
MAINTENANCE HISTORY
CONSISTING OF REPRESENTATIVES OF BOTH THE
AIRLINES AND THE FEDERAL AVAITION
ADMINISTRATION (FAA-US) TO INVESTIGATE
THE CAPABILITIES OF PREVENTIVE
MAINTENANCE.
THE ESTABLISHMENT OF THIS TASK FORCE
SUBSEQUENTLY LED TO THE DEVELOPMENT OF
A SERIES OF GUIDELINES FOR AIRLINES AND
AIRCRAFT MANUFACTURERS TO USE, WHEN
ESTABLISHING MAINTENANCE SCHEDULES FOR
THEIR AIRCRAFT.
RCM PHILOSOPHY EMPLOYS
THESE TECHNIQUES

• PREVENTIVE MAINTENANCE (PM)

• PREDICTIVE MAINTENANCE (PDM)
• REAL-TIME MONITORING (RTM1)
• RUN-TO-FAILURE (RTF - ALSO CALLED
REACTIVE MAINTENANCE)
• PROACTIVE MAINTENANCE
 THE GOAL OF THE RCM
PHILOSOPHY
TO PROVIDE THE STATED FUNCTION OF THE
FACILITY, WITH THE REQUIRED
RELIABILITY AND
AVAILABILITY AT THE LOWEST COST.
RCM REQUIRES THAT MAINTENANCE
DECISIONS BE BASED ON MAINTENANCE
REQUIREMENTS SUPPORTED BY SOUND
TECHNICAL AND ECONOMIC
JUSTIFICATION.
 PRIMARY RCM PRINCIPLES

• RCM IS FUNCTION ORIENTED

– IT SEEKS TO PRESERVE SYSTEM OR
EQUIPMENT FUNCTION, NOT JUST
OPERABILITY FOR OPERABILITY'S SAKE.
– REDUNDANCY OF FUNCTION, THROUGH
MULTIPLE EQUIPMENT,
IMPROVES FUNCTIONAL RELIABILITY, BUT
INCREASES LIFE CYCLE COST IN TERMS OF
PROCUREMENT AND
OPERATING COSTS.
PRIMARY RCM PRINCIPLES
• RCM IS SYSTEM FOCUSED
– IT IS MORE CONCERNED WITH
MAINTAINING SYSTEM
FUNCTION THAN
INDIVIDUAL COMPONENT
FUNCTION.
• RCM IS DRIVEN BY SAFETY
AND ECONOMICS
– SAFETY MUST BE ENSURED AT
ANY COST; THEREAFTER, COST-
EFFECTIVENESS BECOMES THE
CRITERION.
 PRIMARY RCM PRINCIPLES
• RCM IS RELIABILITY CENTERED
– IT TREATS FAILURE STATISTICS IN AN
ACTUARIAL MANNER.
– THE RELATIONSHIP BETWEEN OPERATING
AGE AND THE FAILURES EXPERIENCED IS
IMPORTANT.
– RCM IS NOT OVERLY CONCERNED WITH
SIMPLE FAILURE RATE
– IT SEEKS TO KNOW THE CONDITIONAL
PROBABILITY OF FAILURE AT SPECIFIC AGES
(THE PROBABILITY THAT FAILURE WILL
OCCUR IN EACH GIVEN OPERATING AGE
BRACKET).
 PRIMARY RCM PRINCIPLES
• RCM ACKNOWLEDGES DESIGN
LIMITATIONS
– ITS OBJECTIVE IS TO MAINTAIN THE INHERENT
RELIABILITY OF THE EQUIPMENT DESIGN,
RECOGNIZING THAT CHANGES IN INHERENT
RELIABILITY ARE THE PROVINCE OF DESIGN RATHER
THAN MAINTENANCE.
– RCM RECOGNIZES THAT MAINTENANCE FEEDBACK CAN
IMPROVE ON THE ORIGINAL DESIGN.
– RCM RECOGNIZES THAT A DIFFERENCE OFTEN EXISTS
BETWEEN THE PERCEIVED DESIGN LIFE AND THE
INTRINSIC OR ACTUAL DESIGN LIFE, AND ADDRESSES
THIS THROUGH THE AGE EXPLORATION (AE) PROCESS.
 PRIMARY RCM
PRINCIPLES
• RCM DEFINES FAILURE AS
ANY UNSATISFACTORY
CONDITION
– THEREFORE, FAILURE MAY BE
EITHER A LOSS OF FUNCTION
(OPERATION CEASES) OR A
LOSS OF ACCEPTABLE
QUALITY (OPERATION
CONTINUES).
 PRIMARY RCM
PRINCIPLES

• RCM USES A LOGIC TREE TO

SCREEN MAINTENANCE TASKS
– THIS PROVIDES A CONSISTENT
APPROACH TO THE MAINTENANCE
OF ALL KINDS OF EQUIPMENT.
RCM LOGIC TREE
 PRIMARY RCM PRINCIPLES
• RCM TASKS MUST BE APPLICABLE
– THE TASKS MUST ADDRESS THE
FAILURE MODE AND CONSIDER THE
FAILURE MODE CHARACTERISTICS.
• RCM TASKS MUST BE EFFECTIVE
– THE TASKS MUST REDUCE THE
PROBABILITY OF FAILURE AND BE COST
EFFECTIVE.
 THREE TYPES OF
MAINTENANCE TASKS
• TIME-DIRECTED (PM) – SCHEDULED WHEN
APPROPRIATE.
• CONDITION-DIRECTED (PDM AND REAL-TIME
MONITORING) – PERFORMED WHEN CONDITIONS
INDICATE THEY ARE NEEDED.
• FAILURE FINDING (ONE OF SEVERAL ASPECTS OF
PROACTIVE MAINTENANCE)
– AFTER IT HAS FAILED, INVESTIGATE THE CAUSES OF
FAILURES.
– EQUIPMENT IS RUN-TO-FAILURE.
– THIS IS ACCEPTABLE FOR SOME SITUATIONS AND
SOME TYPES OF EQUIPMENT.
 PRIMARY RCM
PRINCIPLES
• RCM IS A LIVING SYSTEM
– IT GATHERS DATA FROM THE RESULTS
ACHIEVED AND FEEDS THIS DATA BACK
TO IMPROVE DESIGN AND FUTURE
MAINTENANCE.
– THIS FEEDBACK IS AN IMPORTANT PART
OF THE PROACTIVE MAINTENANCE
ELEMENT OF THE RCM PROGRAM.
RCM ANALYSIS CONSIDERS THE
FOLLOWING QUESTIONS
• WHAT DOES THE SYSTEM OR EQUIPMENT DO?
WHAT IS ITS FUNCTION?
• WHAT FUNCTIONAL FAILURES ARE LIKELY TO
OCCUR?
• WHAT ARE THE LIKELY CONSEQUENCES OF
THESE FUNCTIONAL FAILURES?
• WHAT CAN BE DONE TO REDUCE THE
PROBABILITY OF THE FAILURE?
– IDENTIFY THE ONSET OF FAILURE, OR REDUCE THE
CONSEQUENCES OF THE FAILURE?
 RCM IS
APPLICABLE TO…
• WHERE LARGE, COMPLEX
EQUIPMENT IS USED
• WHERE EQUIPMENT FAILURES
POSE SIGNIFICANT ECONOMIC,
SAFETY, OR ENVIRONMENTAL
RISKS.
– AERO / ASTRO INDUSTRIES
– NAVY
– UTILITY COMPANIES
– OFFSHORE INDUSTRY
– MANUFACTURING PROCESS
 BENEFITS OF RCM
QUALITY SERVICE COST TIME RISK
• INCREASED PLANT • BETTER TEAMWORK • OPTIMIZED • SHORTER REPAIR • SAFETY &
AVAILABILITY (2- & MAINTENANCE TIMES. ENVIRONMENTAL
10%). COMMUNICATION. PROGRAM. • REDUCED INTEGRITY A
• ELIMINATION OF • IMPROVED • REDUCED LEVELS DURATION OF PRIORITY.
CHRONIC FAILURES UNDERSTANDING OF SCHEDULED SCHEDULED • FAILURES WITH
& INHERENT OF CUSTOMER MAINTENANCE OVERHAULS. UNACCEPTABLE
RELIABILITY REQUIREMENTS. (10-50%). • EXTENDED CONSEQUENCES
PROBLEMS. • LESS DISRUPTION • BETTER PERIODS BETWEEN MUST BE DEALT
• FLEXIBILITY TO OF PRODUCTION MAINTENANCE OVERHAULS (60- WITH.
ACCOMMODATE PROCESSES DUE TO CONTRACT 300%). • REDUCED
PRODUCTION UNPLANNED ADMINISTRATION. LIKELIHOOD OF
REQUIREMENTS. BREAKDOWNS. • CLEAR MULTIPLE
• DOCUMENTED GUIDELINES FOR FAILURES.
BASES FOR APPLICATION OF • REDUCED
MAINTENANCE NEW NUMBERS OF
PROGRAM. MAINTENANCE ROUTINE, EVASIVE
• IMPROVED TECHNOLOGY. TASKS.
OWNERSHIP FOR • LONGER LIFE OF • REDUCED RISK TO
MAINTENANCE EXPENSIVE PLANT
PROGRAM. EQUIPMENTS. MAINTENANCE
• REDUCTION IN WORKERS.
SECONDARY
DAMAGE.
 INSTITUTING AN RCM
PROGRAM DEPEND ON…
• NATURE OF THE
BUSINESS
• RISKS POSED BY
EQUIPMENT FAILURE
• STATE OF THE EXISTING
MAINTENANCE PROGRAM
 TO DEVELOP AN RCM
PROGRAM
• WHAT ASSETS ARE OWNED & OPERATED
BY THE COMPANY?
• TO WHICH OF THESE SHOULD RCM BE
APPLIED?
• WHAT ARE THE FUNCTIONS &
PERFORMANCE EXPECTATIONS OF EACH
SELECTED ASSET?
• IN WHAT WAYS CAN IT FAIL TO PERFORM
THESE FUNCTIONS?
 TO DEVELOP AN RCM
PROGRAM
• WHAT CAUSES IT TO FAIL?
• WHAT ARE THE CONSEQUENCES OF EACH
FAILURE?
• WHAT SHOULD BE DONE TO PREVENT
EACH FAILURE?
• WHAT STEPS SHOULD BE TAKEN IF
PREVENTIVE MEASURES CAN’T BE FOUND?
PURPOSE OF THE RCM
REVIEW PROCESS
TO DEFINE THE MAINTENANCE
REQUIREMENTS FOR A PHYSICAL
ASSET THAT ARE NECESSARY TO
MEET THE BUSINESS OBJECTIVES.
THE LEVEL OF PERFORMANCE
REFLECTS WHAT IS REQUIRED OR
WANTED FROM THE ASSET.
MAJOR STEPS IN THE RCM
REVIEW PROCESS
STEP 1
SELECT PLANT AREAS THAT MATTER
STEP 2
DETERMINE KEY FUNCTIONS &
PRODUCTIVITY GOALS
STEP 3
DETERMINE PLAUSIBLE FUNCTIONAL
FAILURES
STEP 4
DETERMINE LIKELY FAILURE MODES &
THEIR EFFECTS
MAJOR STEPS IN THE RCM
REVIEW PROCESS
STEP 5
SELECT FEASIBLE & EFFECTIVE
MAINTENANCE TACTICS
STEP 6
IMPLEMENT SELECTED TACTICS
STEP 7
OPTIMIZE TACTICS & PROGRAMS
 STEP 1 - SELECT PLANT
AREAS THAT MATTER
IDENTIFY & PRIORITIZE THE PHYSICAL
RESOURCES.
• ESTABLISH A STRUCTURED,
COMPREHENSIVE LIST OF ALL
PHYSICAL ASSETS OWNED OR
USED THAT REQUIRE SOME FORM
OF MAINTENANCE OR
ENGINEERING ATTENTION.
– PLANT REGISTER, PLANT INVENTORY,
OR EQUIPMENT FAMILY TREE
 STEP 1 - SELECT PLANT
AREAS THAT MATTER
• ASSESS THE IMPACT OF THE
PHYSICAL RESOURCES ON THE
KEY BUSINESS PERFORMANCE
AREA.
– AVAILABILITY
– PROCESS CAPABILITY
– QUALITY
– COSTS
– SAFETY/ENVIRONMENTAL RISKS
STEP 1 - SELECT PLANT AREAS
THAT MATTER

• ESTABLISH THE BOUNDARIES

BETWEEN EQUIPMENT SYSTEMS.
–DEFINES THE SCOPE OF THE
REVIEW & ORGANIZES IT INTO
MANAGEABLE PIECES.
STEP 2 – DETERMINE KEY
FUNCTIONS &
PRODUCTIVITY GOALS

THE PURPOSE OF THE

MAINTENANCE TACTIC IS TO
MAKE SURE THE EQUIPMENT IS
WORKING PROPERLY &
PRODUCING ON SCHEDULE.
 STEP 2 – DETERMINE KEY
FUNCTIONS &
PRODUCTIVITY GOALS
• CATEGORIES OF PHYSICAL ASSETS IN
TERMS OF FUNCTION
– PRIMARY – WHY THE EQUIPMENT EXISTS AT
ALL.
– SECONDARY – LESS OBVIOUS PRIMARY
FUNCTION BUT THE CONSEQUENCES OF
FAILURE MAY BE NO LESS SEVERE.
– PROTECTIVE
 STEP 2 – DETERMINE KEY
FUNCTIONS &
PRODUCTIVITY GOALS

• MAINTENANCE PERFORMANCE
MAY BE DEFINED IN TERMS OF …
– BUILT-IN – WHAT IT CAN DO
– REQUIRED – WHAT WE WANT IT TO
DO
– ACTUAL – WHAT IT IS DOING
STEP 3 – DETERMINE PLAUSIBLE
FUNCTIONAL FAILURES

• FUNCTIONAL FAILURES
–TOTAL LOSS OF FUNCTION
–PARTIAL LOSS OF FUNCTION
–MULTIPLE LEVELS OF PERFORMANCE
EXPECTED FROM AN INDIVIDUAL
FUNCTION.
 STEP 4 – DETERMINE LIKELY
FAILURE MODES AND THEIR
EFFECTS

• LIKELY FAILURE MODES

– THOSE THAT OCCURRED ON THE SAME OR
SIMILAR EQUIPMENT.
– THOSE ALREADY THE SUBJECT OF PREVENTIVE
MAINTENANCE TASKS.
– THOSE THAT HAVE NOT HAPPENED BUT ARE
CONSIDERED POSSIBLE BECAUSE OF
EXPERIENCE OR VENDOR/MANUFACTURER
RECOMMENDATIONS.
 STEP 4 – DETERMINE LIKELY
FAILURE MODES AND THEIR
EFFECTS
• WHEN A FAILURE MODE OCCURS, OBTAIN THE
FOLLOWING INFORMATION.
– THE EVIDENCE OF THE FAILURE TO THE OPERATING
CREW UNDER NORMAL CONDITIONS.
– THE HAZARDS THE FAILURE MAY POSE TO WORKER
SAFETY, PUBLIC SAFETY, PROCESS STABILITY, OR
THE ENVIRONMENT.
– THE EFFECT ON PRODUCTION OUTPUT AND
MAINTENANCE.
 STEP 5 – SELECT FEASIBLE AND
EFFECTIVE MAINTENANCE
TACTICS
• PREVENTIVE MAINTENANCE TACTICS
MUST BE …
– TECHNICALLY FEASIBLE – DEAL EFFECTIVELY
WITH THE TECHNICAL CHARACTERISTIC OF
THE FAILURE.
– COST-EFFECTIVE – REDUCING OR AVOIDING
PITFALLS IN LINE WITH COSTS AND
OPERATING CONSTRAINTS.
 STEP 6 – IMPLEMENT
SELECTED TACTICS
• ACTIONS NEEDED TO PUT THE MAINTENANCE TACTICS
INTO EFFECT.
– TWEAKING MAINTENANCE SCHEDULES.
– DEVELOPING OR REVISING TASKS INSTRUCTIONS.
– SPECIFYING SPARE PARTS AND ADJUSTING INVENTORY
LEVELS.
– ACQUIRING DIAGNOSTIC OR TEST EQUIPMENT.
– REVISING OPERATION AND MAINTENANCE PROCEDURES.
– SPECIFYING THE NEED FOR REPAIR OR RESTORATION
PROCEDURES.
– CONDUCTING TRAINING IN THE NEW PROCEDURES.
STEP 7 – OPTIMIZE TACTICS
AND PROGRAM

THE OBJECTIVE OF THIS ONGOING

ACTIVITIES ARE TO REDUCE EQUIPMENT
FAILURE, IMPROVE MAINTENANCE
EFFECTIVENESS, THE USE OF
RESOURCES, IDENTIFY THE NEED TO
EXPAND THE REVIEW, AND REACT TO
THE CHANGING INDUSTRY OR ECONOMIC
CONDITIONS.
 STEP 7 – OPTIMIZE
TACTICS AND PROGRAM
• COMPLIMENTARY ACTIVITIES
– PERIODIC RE-ASSESSMENT AND REVISION OF
THE RCM REVIEW RESULTS.
– CONTINUOUS PROCESS OF MONITORING,
FEEDBACK, AND ADAPTATION.
• ANALYZES AND ASSESSES THE DATA PRODUCED BY
PRODUCTION AND MAINTENANCE ACTIVITIES FOR
FAILURE RATES, CAUSES, AND TRENDS.
• VARIANCES BETWEEN ACTUAL AND TARGET
PERFORMANCE.
 RCM KEY SUCCESS
FACTORS
• CLEAR PROJECT GOALS
• MANAGEMENT SUPPORT &
A COMMITMENT TO
INTRODUCE A CONTROLLED
MAINTENANCE
MANAGEMENT.
• UNION INVOLVEMENT
• GOOD UNDERSTANDING OF
RCM PHILOSOPHY BY
PLANT STAFF.
 RCM KEY SUCCESS FACTORS
• PILOT RCM APPLICATIONS TO DEMONSTRATE
SUCCESS & BUILD SUPPORT.
• SUFFICIENT RESOURCES FOR BOTH THE REVIEW
AND SUBSEQUENT IMPLEMENTATION OF
RECOMMENDATIONS.
• CLEAR DOCUMENTATION OF RESULTS TO
FACILITATE ACCEPTANCE OF
RECOMMENDATIONS.
• INTEGRATION WITH CONDITION-BASED
MAINTENANCE CAPABILITY.
RCM IMPLEMENTATION PHASES
Phase 1: Prepare Phase 2: Demonstrate Phase 3: Execute
• Assess
maintenance
capability &
environment. • Conduct
• Transfer
• Customize facilitator &
training.
training. team member
• Institutionalize
• Conduct training.
RCM review.
awareness • Conduct pilot
• Implement
training. applications.
system
• Target • Revise plans &
improvements.
physical training
• Implement
resources. programs.
“living
• Develop • Develop “living
program”.
project plans. program” plan.
• Estimate
costs/benefits
.
 RELIABILITY-CENTERED
MAINTENANCE (RCM)
RELIABILITY-CENTERED MAINTENANCE IS
THE PROCESS OF DETERMINING THE
MOST EFFECTIVE MAINTENANCE
APPROACH.
AS THE AIRLINE INDUSTRY SHOWED 40
YEARS AGO, RCM CAN NOT ONLY IMPROVE
THE RELIABILITY OF A SYSTEM, IT CAN
SIGNIFICANTLY REDUCE THE REQUIRED
MAINTENANCE.
 RELIABILITY-CENTERED
MAINTENANCE (RCM)
IN TODAY'S COMPETITIVE WORLD
ECONOMY, THAT TRANSLATES
INTO A LOT OF MONEY SAVED,
BOTH FROM REDUCED FAILURES
AND REDUCED WORK.
A PROPERLY IMPLEMENTED RCM
PROGRAM WILL CONTINUE
SAVING MONEY YEAR AFTER YEAR.
 RELIABILITY-CENTERED
MAINTENANCE (RCM)

TO REMAIN COMPETITIVE MOST

COMPANIES CAN NO LONGER AFFORD
TO REMAIN ON THE SIDELINES DOING
THINGS LIKE THEY'VE ALWAYS DONE.
LET RCM MOVE THE MAINTENANCE
PROGRAM INTO THE 21ST CENTURY.