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Reliability Centered Maintenance & Maintenance Planning Jordan Holt Director Performance Improvement

Francesco Palmeri | CRE. PMP, PE Director Reliability Centered Maintenance Planning

Washington Metropolitan Area Transit Authority

Key References

a. Nowlan & Heap (Dec 1978), Reliability Centered Maintenance, United Airlines, San Francisco, CA, USA.

b. John Moubray (1990), RCM2, Industrial Press Inc, NY, USA

c. SAE International Standard JA1011 (Aug 2009), Evaluation Criteria for RCM Processes

d. SAE International Recommended Practice JA1012 (Aug 2011), A Guide to the RCM Standard

e. Marius Basson (2018), RCM3, Industrial Press Inc, NY, USA

Another very useful reference

a. Doc Palmer (1999), Maintenance Planning & Scheduling 3rd Edition, McGraw Hill, NY, USA

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•

• •

•

Historical Timeline of the Notable Developments in RCM

MSG in aviation

1960 MSG 1&2 deveby aviation industry

loped 1980 MSG3

1988 MSG3 Rev 1

1993 MSG3 Rev 2 2001 MSG3.2 001

2002 MSG3.2 002

The development of RCM

1978 Nowlan & Heap

1981 RCM appli

1986

report “RCM” pub

ed outside aviation for the first time

MIL STD 2173 Nav

lished

air 404 NES 45

1999 SAE JA1011 & SAE JA1012

Aladon RCM2/3

1990 John Moubray “RCM2”

2004 “RCM3” Risk-based RCM

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1960 1970 1980 1990 2000 2010 2020 WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY 3

Formal Definitions

What is Reliability Centered Maintenance (RCM)? Nowlan & Heap: A logical discipline for the development of scheduled maintenance programs to realize the inherent reliability capabilities of equipment.

RCM2: A process used to determine what must be done to ensure that any physical asset continues to do what its users want it to do in its current operating context.

RCM3: A process used to define the minimum required safe amount of maintenance, engineering and other risk management strategies to ensure a tolerable level of safety and environmental integrity and cost effective operational capability as specified in the organization’s asset management standards.

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Steps of the RCM3 Process

The eight (8) steps of RCM3: Step 1: What are the operating conditions? (Define the operating context) Step 2: What are the functions & performance stds? (What do users want it to do) Step 3: In what ways can it fail? (Define the failed states) Step 4: What causes it to fail? (Determine failure causes & mechanisms) Step 5: What happens when it fails? (Determine failure effects & consequences) Step 6: What are the risks associated with each failure? (Inherent risks) Step 7: What must be done to reduce intolerable risks to a tolerable level? (Proactive risk management)

Step 8: Can anything be done to reduce tolerable risks in a cost effective way? (Default risk management)

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Proactive Risk Management

Risk = Probability x Consequences

In order to reduce an Intolerable risk to a Tolerable level, we have three (3) choices. We could:

a. Reduce the Probability of occurrence through proactive maintenance,

b. Reduce the Severity of consequences through a one-time change (modification, training, change in process or procedures),

c. If possible; do both (depending on the severity of the consequences).

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Proactive Task Options

Predictive or condition-based maintenance

Preventive maintenance – scheduled restorations

Preventive maintenance – scheduled discards

Failure finding tasks (only for protective devices)

Functional checks

One-time changes (Modification, Training, Procedures).

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Fundamentals of Maintenance & Reliability

Generation I – Maintenance / Design Philosophy Run everything to failure - repair or replace as required (Run to failure)

Generation II – Maintenance / Design Philosophy Assume all components have a useful life limit. Replace components before they reach that useful life limit (Safe life)

Add redundancy (Fail safe)

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Fundamentals of Maintenance & Reliability

Generation III – Maintenance / Design Philosophy Design for Reliability - only do maintenance when required (Damage tolerant) Introduce Condition Monitoring Adopt a Condition Based Maintenance approach

Generation IV – Maintenance / Design Philosophy Industrial Internet (IIoT) Making use of the real time data capture and wireless technology Integration with the Computerized Maintenance Management System

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I I I I I I I I I I I I I I I I

I I I I I I I I I I I

~

Fundamentals of Maintenance & Reliability

Idealized bathtub curve model for the time to failure of a component Hazard Rate

Time

Useful Life Infant Mortality Wear Out

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--------

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Fundamentals of Maintenance & Reliability

Idealized effect of Maintenance on the bathtub curve

Preventative

Haza

rd R

ate

Useful Life Infant

Mortality Wear Out

Maintenance

Extension of Useful Life

Time 11

~~-----------------------------------------

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Fundamentals of Maintenance & Reliability

Realistic effect of Maintenance on the bathtub curve Ha

zard

Rat

e

• Maintenance • Overhauls • Modifications

Reemergence of the Infant Mortality

Region

Time 12

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I I I I I

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Fundamentals of Maintenance & Reliability

Idealized view of maintenance optimization Ha

zard

Rat

e

Useful Life Infant

Mortality Wear Out

Best window to perform

maintenance

Time 13

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b

Historical Failure Patterns

Research shows the following six failure patterns across many industries. Originally performed by United Airlines and Boeing as part of the 747 program (MSG 1 & 2)

4%4%4% AAA

2 %2 %2 % BBB

5 %5 %5 % CCC

7 %7 %7 % DDD

E14 %14 %14 % EE

F68 %68 %68 % FF

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11% - Might benefit from

limit on operating age

89% -No benefit

from limit on operating age

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Useful Life

Mean Life

Average Lost Life

Explaining Useful Life

Time

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What does all this mean for WMATA

Historically, WMATA relies on OEM maintenance program for the entire lifecycle of our Assets’

Time Based Maintenance is prevalent

Little to No consideration of Operational Performance and/or Changes to our Operating Context

Little to No consideration of adopting a Condition Based Maintenance approach

PM Compliance is consistently above 90% and yet over 40% of our maintenance is corrective action

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Benefits of Adopting a Condition Based Maintenance Approach

P- F Interval

Cond

ition

Time

Condition Monitoring allows you to maximize the P-F Interval and move to a Proactive maintenance culture

F Point where

Failure occurs

Point where Failure begins

P

Point where Failure can start to be

Measured

Oil Analysis (Months)

Thermography (Weeks)

Vibration (Weeks - Months)

Acoustics (Weeks)

Smoke (Secs)

Heat (Days)

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RCM3 Decision Diagram

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Documeot Work_

RCM & Maintenance Planning

**Analyze performance** of programs in place and loop back if further refinement required

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RCM & Maintenance Planning

RCM at WMATA Around 100 people trained via six 3-day sessions Six deep dives conducted with 7th planned

• Chosen based on reliability reporting • Switches, track circuits, DC breakers, Track/third rail, Railcar pneumatic system, Railcar doors

• Two weeks (about a week on proces and a second week on the system) • Cross-section of maintenance, operations and engineering staff

Working through implementing deep dive recommendations

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Common Myths about RCM

“It’s too hard…”

“It takes too long…”

“It’s too expensive….”

“That’s just an Aviation thing; it won’t work in our industry….”

“That’s just another name for condition monitoring….”

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Summary

RCM is a process (structured, scientific, repeatable, defendable)

It is not new…….RCM has been around for over 40 years

When applied correctly, RCM will provide the best maintenance program for your Asset given the Operating Context & Risk profile.

Step 7 provides the pathway for addressing Risk proactively

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