IFS ApplIcAtIonS™ FoR

RElIABIlItY cEntERED MAIntEnAncEAchieve mAximum operAtionAl AvAilAbility with sAfe but minimum levels of mAintenAnce

oUR SolUtIon’S DnA

when we first set out to create ifs Applications over 25 years ago, our goal was to make the most usable business software on the market. And to help us achieve that ambition, we put simplicity at the forefront of everything we did.

We still do.

we decided that we would make only one product, which can be easily configured to match the specific requirements of a broad range of industries.

We still do.

we decided that we would build ifs Applications on standards so our customers would not be locked into any particular technology.

We still do.

we decided to design ifs Applications as a component-based structure so it can be easily extended and updated.

We still do.

we decided that each software component must be totally compatible with every other, yet capable of running independently.

We still do.

we decided to build a product that could handle change and long-term evolution.

We still do.

And, that we would make the most user-friendly business software on the market.

We still do that, too.

3RELIABILITY CENTERED MAINTENANCE

IFS RElIABIlItY cEntERED MAIntEnAncEReliability centered Maintenance (RcM) is the 21st century, defensible, methodical and scientific approach to the establishment of safe minimum levels of maintenance. It also supports changes to operating procedures and strategies and the establish-ment of capital maintenance regimes and plans. this leads to increases in cost effectiveness, equipment uptime, and a greater understanding of the level of risk that an organization is presently managing.

WHY RcM? Historically, the traditional approach to maintenance planning by service and maintenance engineers applied the premise that it is better to have a pre-ventive service and maintenance regime than one based on only repair when there is a failure.

However, history has proved time and time again that invasive maintenance can compound the situation and introduce further failure.

RCM uses a range of approaches, within a decision framework, to deliver the optimum main-tenance strategy for complex, safety-critical assets, balancing risk, cost and environmental factors to extend ‘through life expectancy’.

WHAt MAKES RcM DIFFEREnt? The origins of the RCM approach were based in the need to manage the increasing equipment complexity and costs within the aviation industry. The driver was to improve safety records in the 1960s and 70s, during the transition between propeller and jet propulsion technology.

RCM also has its origins in a key study commis-sioned by the US DOD (carried out by Nowlan and Heap from United Airlines) in 1978. The Nowlan

and Heap study found that the fundamental assump-tions made by design and maintenance planners on the expected life of reliable service from components such as aero engines, undercarriage, navigation systems etc. were wrong in almost every specific example in a complex jet airliner. These findings created a paradigm shift in the understanding of failure management, including:• arealizationthatthevastmajorityoffailuresare

not necessarily linked to the age of the asset;• theneedtofocusonmanagingtheprocessof

failure rather than trying to predict life expectancy;• aneedtounderstandthedifferencesbetween

the user requirements of an asset compared with the design capability;

• aneedforanunderstandingofthemanagementof the condition of an asset;

• astrategytolinkthelevelsoftolerablerisktomaintenance strategy development.

These initial findings were further developed by Moubray in his industry-leading book RCM II, firstpublishedin1991.HerehecharacterizedRCMas a process to establish the maintenance require-ments of a physical asset in its operating context and an engineering framework that enables the definition of a complete maintenance regime. Fundamentally, RCM regards maintenance as the means to maintain the functions a user may require of equipment in a defined operating context. It does this by taking a detailed approach to individual components within equipment, such as a pump, while also addressing how the pump fits holistically into the asset in which it operates, together with the performance criteria and safety-related issues that have been established for the asset.

4 RELIABILITY CENTERED MAINTENANCE

Managers with responsibilities for asset performance —principally for reliability and availability—face a significant challenge in selecting the most appropriate technique in the face of several different failure types.

IFS uses RCM to support a structured decision- support process that consists of the following steps:• definethemaintenanceproblemandgather

basic information;• definethefunctionsanddesiredperformance

standards for each item of equipment;• defineallthewaysinwhichitcanfailtodeliver

the required performance (functional failures);• establishthecausesoffailure(failuremodes);• recordwhathappenswheneachfailuremode

occurs (failure effects);• establishastrategyfordealingwitheachfailure

mode based on an assessment of failure conse-quences (protection which is not fail-safe, failures which endanger life or the environment, failureswhichaffecttheorganization’sbusinessobjectives, failures that only involve the cost of repair);

• assesstheapplicabilityofdifferenttypesof failure prevention and establish task frequencies (condition-based maintenance tasks, scheduled overhaul tasks and scheduled discard tasks).

IFS Applications provides the framework within asoftwarebusinesssolutiontohelporganizationsdevelop an RCM strategy, and collect the data, for the management of complex and mission critical assets.

gEttIng StARtED WItH RcM

traditional

BathtuB

Slow aging

BeSt new

random

worSt new

1940 1950 1960 1970 1980 1990

reactive maintenance: fix it when it breaks

Preventative maintenance: scheduled overhauls and replacements

Predictive maintenance: e.g. Conditionmonitoring

detective maintenance:risk management

1940

’s

1950

’s

1960

’s

1970

’s

1980

’s

1990

’s

2000

’s

2010

’s

acknowledged Failure Patterns

evolving maintenance Strategies

5RELIABILITY CENTERED MAINTENANCE

there are some 450 global customers of the IFS RcM toolkit. the footprint includes such diverse industries as oil production, Vineyards and Wine production, Defense and the chemical industry.

RCM should be used in any industry that imple-ments complex or capital intensive assets or is reliant on correctly functioning assets to provide an output.

RCM provides an industry standard to define a maintenance program, creating a cost-effective maintenance strategy to address dominant causes of equipment failure. It ensures that Safety, Environmental and Operational failures are mini-mized,whilereducingover-maintenance.Itresultsina maintenance program that focuses scarce economic resources on those items that would cause the most disruption if they were to fail.

RCM can provide you with a systematic approach tooptimizingyourassetmaintenance.Successfulimplementation of RCM will lead to an increase in cost effectiveness, machine uptime, and a greater understanding of the level of risk that your organi-zationispresentlymanaging.

cASE StUDY BEnEFItS USIng IFS RcMThe UK Royal Navy has implemented IFS and RCM throughout its fleet. It predicted a consider-able reduction of maintenance, while still ensuring that safety and operation are maintained, even in safety-critical assets such as nuclear submarines.IFS has supported the delivery of key benefits through its IFS RCM Toolkits, and the UK Royal Navy has seen a significant return on investment, including:

• ACpowergeneration&distributionmaintenancereduced some 45%

• Steamsystemmaintenanceanddieselgeneratormaintenance reduced by over 60%

• HPairsystemmaintenancereducedbymorethan 52%

• Radar&ESMmaintenancereducedbyatleast65%

• Lubricationoilsystemmaintenancereduced by nearly 70%

• Sonarmaintenancereducedbynearly50%

tHE IFS RcM toolKIt—tHE lEADIng IntEgRAtED RcM SolUtIon

WHAt RcM cAn Do FoR YoU

con

stru

ctio

n, contrActinG & service mAnAGement

utili

ties & telecom

process mAnufActurinG m

AnufActurinG

Auto

motive

Aero

spAce & Defense

retA

il & wholesAle

6 RELIABILITY CENTERED MAINTENANCE

IFS’ RcM toolKItIFS’ RcM toolkit enables storage of maintenance strategies derived using RcM analysis techniques in a database. It is specifically targeted to deliver the optimum maintenance strategy for complex, safety critical assets, balancing risk, cost and environmental factors to extend ‘through life expectancy’.

The IFS RCM Toolkit delivers core RCM process support capability using the latest presentation technology. It supports the criteria for RCM (SAE JA1011). Customers also have the option to use the RCM Toolkit delivered through Software as a Service (SAAS). Training and consultancy is available using our strategic partners.

the RcM toolkit:• Providesanindustrystandardtodefineamain-

tenance program• Createsacost-effectivemaintenancestrategyto

address dominant causes of equipment failure• EnsuresSafety,EnvironmentalandOperationalfailuresareminimized

• Helpsreduceover-maintenance—acknowledgesthat the majority of failures are not age-related

• Resultsinamaintenanceprogramthatfocusesscarce economic resources on those items that would cause the most disruption if they were to fail.

7RELIABILITY CENTERED MAINTENANCE

• Supportsanauditableanddefensible maintenance strategy—exercising duty of care

• Reducedthroughlifecosts—Referenceablecases reported 20% savings through correct application of iFS rCm.

• Overallmaintenanceburdenisreduced —Personnel stretch eased.

• Operationalavailabilityisincreased.

• Greaterunderstandingofequipmentby all involved—with risks documented to aid maintenance deferral/deployment decisions.

• Ownershipofresults

BEnEFItS to YoUR oRgAnIZAtIon

RcM Authoring tool authoring of rCm analyses Fully configurable to meet diverse industrial needs

Workflow Versioning and approvals workflow capability

aids control and rigor of output production to improve efficiency

FMEcA toolFmeCa (Failure mode, effects and Criticality analysis)

intuitive entry for Failure mode, effects and Criticality informa-tion significantly aids ease of use and thus productivity

Failure Management Strategy

maintenance tasks and intervals

defined schedules aid planning and spares procurement

Standards Supports multiple standards user configurable, e.g. rCm 2, defStan 00-45, etc.

FFI calculator Built-in Failure Finding interval Calculator

aids effective determination of maintenance intervals

RcM Analysisvalidation

auto-validation automatic analysis validation based on the user-defined standard aids Qa

Report generation Standard reports Proven pre-formatted industry-standard reports

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www.IFSDEFEncE.comthiS doCument may Contain StatementS oF PoSSiBle Future FunCtionality For iFS’ SoFtware ProduCtS and teChnology. SuCh StatementS oF Future FunCtionality are For inFormation PurPoSeS only and Should not Be interPreted aS any Commitment or rePreSentation. iFS and all iFS ProduCt nameS are trademarkS oF iFS. the nameS oF aCtual ComPanieS and ProduCtS mentioned herein may Be the trademarkS oF their reSPeCtiVe ownerS.

iFS aB ©2012

iFS is a public company (omX Sto: iFS) founded in 1983 that develops, supplies, and implements iFS applications™, a component-based extended erP suite built on Soa technology. iFS focuses on agile businesses where any of four core processes are strategic: service & asset management, manufacturing, supply chain and projects. the company has more than 2,000 customers and is present in 50+ countries with 2,700 employees in total. if you are interested in further information, e-mail info@ifsdefence.com or contact one of our regional offices or visit our web site: www.IFSDEFEncE.com

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