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  • AD-A236 693 NAVAL WAC OLLEGE i >- "NEWPORT, RHODE ISLAND

    RELIABILITY CENTERED MAINTENANCE

    by

    R.E. LOVE

    MAJOR, UNITED STATES MARINE CORPS

    A paper submitted to the faculty of the Naval War College in partial satisfaction of the requirements of the Department of Operations.

    The contents of this paper reflect my own personal views and are not necessarily endorsed by the Naval War College or the Department of the Navy.

    Signa ture ____

    21 June 1991

    , :: -.. k] I- Paper directed by Captain Dunne, USN

    and --.. .... . . . CDR Codner, RN

    i t .. : A,,_" I .,,'"te-e

    i ~~~~~~~~ 0^ li\ I II III|||

  • SEITYCLASFATION OF THISPAG Form Approved

    REPORT DOCUMENTATION PAGE OMB No. 0704-018 Is REPORT SECURITY CLASSIFICATION Ib RESTRICTIVE MARKINGS

    UNCLASSIFIED 2a. SECURITY CLASSIFICATION AUTHORITY LDLST TA(IA"IATY OF REPORT

    LJJbTRBUTON TATMET A: Approved

    2b DECLASSIFICATIONIDOWNGRADING SCHEDULE for public release; distribution isunlimited.

    4. PERFORMING ORGANIZATION REPORT NUMBER(S) S MONITORING ORGANIZATION REPORT NUMBER(S)

    6a NAME OF PERFORMING ORGANIZATION 6b OFFICE SYMBOL 7a NAME OF MONITORING ORGANIZATION(if applicable)

    OPERATIONS DEPARTMENT C

    6c. ADDRESS (City, State, and ZIP Code) 7b ADDRESS (City, State, and ZIP Code)

    NAVAL WAR COLLEGE NEWPORT, R.I. 02841

    8a. NAME OF FUNDINGISPONSORING 8b. OFFICE SYMBOL 9 PROCUREMENT INSTRUMENT IDENTIFICATION NUMBER A ORGANIZATION (If applicable)

    ic. ADDRESS (City, State, and ZIP Code) 10 SOURCE OF FUNDING NUMBERS PROGRAM PROJECT TASK WORK UNIT ELEMENT NO NO NO ACCESSION NO

    11 TITLE (Include Security Classification)

    RELIABILITY CENTERED MAINTENANCE (U)

    12. PERSONAL AUTHOR(S)

    MAJOR ROBERT E. LOVE, UNITED STATES MARINE CORPS 13a. TYPE OF REPORT 13b TIME COVERED 14. DATE OF REPORT (Year, Month, Day) 15 PAGE COUNT

    FINAL FROM TO 910211 31 16 SUPPLEMENTARY NOTATION A paper submitted to the Faculty of the Naval War College in partial satisfac on of the requirements of tha Depart ent of 0pe e cote or.this 8ayfr relect own personai views anu ar no? necessary en orseo y he eaval war ~o iege or the uepartment of the Navy.

    17. COSATI CODES 18 SUBJECT TERMS (Continue on reverse if necessary and identify by block number) FIELD GROUP SUB-GROUP RCM, PM, CM, Reliability, Maintenance

    19 ABSTRACT (Continue on reverse if necessary and identify by block number)

    This paper addresses the requirement for Reliability Centered Maintenance (RCM) in fielded weapon systems. While Reliability Centered Maintenance is incorporated into developing weapon systems through the Logistics Support Analysis process it is not fully utilized in the post production process. Systems fielded with the benefit of Reliability Centered Maintenance are not routinely revisited to ensure that the inherent reliability of the system is being achieved. Preventive maintenance tasks are modified primarily as a result of user response and not through the integrated use of usage data and viable engineering analysis. The use of Reliability Centered Maintenance as an alternative maintenance strategy, service wide, is recommended to ensure that the inherent reliability of a weapon system is realized at minimum cost.

    20 DISTRIBUTION /AVAILABILITY OF ABSTRACT 21 ABSTRACT SECURITY CLASSIFICATION (MUNCLASSIFIED/UNLIMITED 0 SAME AS RPT 0 DTIC USERS UNCLASSIFIED

    2Za NAME OF RESPONSIBLE INDIVIDUAL 22b TELEPHONE (include Area Code) 22c OFFICE SYMBOL Chairman, Operations Department 401-841-3114 C

    DD Form 1473, JUN 86 Previous editions are obsolete SECURITY CLASSIFICATION OF THIS PAGE

    S/N 0102-LF-014-6603 UNCLASSIFIED

  • ABSTRACT

    This paper addresses the requirement for Reliability Centered

    Maintenance (RCM) in fielded weapon systems. While RCM is

    incorporated into developing weapon systems through the Logistics

    Support Analysis (LSA) process, it is not fully utilized in the

    post production process. Systems fielded with the benefit of RCM

    are not routinely revisited to ensure that the inherent

    reliability is being achieved. Preventive maintenance tasks are

    modified, primarily as a result of user response and not through

    the integrated use of usage data and viable engineering analysis.

    The use of Reliability Centered Maintenance as an alternative

    maintenance strategy, service wide, is recommended to ensure that

    the inherent reliability of a weapon system is realized at minimum

    cost.

    ii

    91-01538 049~E luli li 1311111 l llo4

  • TABLE OF CONTENTS

    CHAPTER PAGE

    ABSTRACT......................................... ii

    TABLE OF CONTENTS .................................i.1

    I INTRODUCTION............................ 1

    II HISTORICAL PERSPECTIVE ................... 3

    III RELIABILITY CENTERED MAINTENANCE ........ 5 Overview.............................. 5 Concept............................... 6 Preventive Maintenance ................. 7 Failure Analysis ....................... 9 Failure Modes Effects and Criticality Analysis .................. 10

    IV RELIABILITY CENTERED MAINTENANCE PROCESS................................. 12

    Age Exploration ....................... 14 Packaging of Maintenance Tasks ........ 15

    V POST PRODUCTION APPLICATION ............. 17 Reliability.......................... 17 Fielded Equipment ..................... 18 Auditing............................. 24

    VI CONCLUSIONS............................ 25

    ENDNOTES......................................... 27

    BIBLIOGRAPHY..................................... 28

  • CHAPTER I

    INTRODUCTION

    "The limitation imposed upon operations by logistics represents the final limit of a commander's plan of action."

    Sound Military Decision, 1942

    The traditional approach to performing preventive maintenance

    is to acknowledge the relationship between the age of a particular

    item and its life expectancy. Historically, this meant that at a

    certain point in the life of an item it would be rebuilt or

    replaced regardless of its actual condition. Maintenance was

    performed on a time directed criteria (e.g. bimonthly, annually

    etc.). A significant amount of time and effort would be expended

    bringing the item into a maintenance facility, taking the

    appropriate action, and returning the asset to service. An

    additional cost could be attributed to the loss of the operational

    availability of the item during the period of servicing. This

    paper will present the Reliability Centered Maintenance concept as

    an alternative maintenance strategy for developing and or refining

    preventive maintenance tasks and schedules.

    The concept of Reliability Centered Maintenance evolved as an

    alternative to the traditional approach in an effort to restore

    the inherent reliability of a system at the minimum cost.

    Reliability Centered Maintenance is used by all services in the

    Logistics Support Analysis (LSA) process. While LSA and

    Reliability Centered Maintenance serve as a fundamental

    1

  • requirement in systems design and development, the Reliability

    Centered Maintenance concept has not been accepted into the post

    production phase of a weapon systems life. Although current

    directives require its use, Reliability Centered Maintenance has

    not been accepted for refinement or development of preventive

    maintenance tasks in the post production phase of a weapon systems

    life cycle.

    The reader is presented with sufficient information to

    understand the Reliability Centered Maintenance program,

    appreciate its' capabilities and potential value added to

    applicable weapon systems. Chapter II of this paper reviews the

    historical basis for the Reliability Centered Maintenance program.

    Chapter III provides the reader with an overview of the underlying

    concept behind Reliability Centered Maintenance, to include a

    discussion of preventive maintenance and failure analysis.

    Chapter IV describes the principle methodologies involved in the

    process. Chapter V is a discussion of post production application

    of Reliability Centered Maintenance based on the preceding

    chapters. Conclusions are presented in the last chapter and

    suggest that Reliability Centered Maintenance is a viable

    maintenance strategy for post production weapon systems.

    2

  • CHAPTER II

    HISTORICAL PERSPECTIVE

    In 1968 the Federal Aviation Administration (FAA) expressed a

    desire to utilize a new concept in the initial maintenance program

    for the Boeing 747. This concept, later to be known as the

    Management Steering Group-i (MSG-1), was integrated into the

    design of the Boeing Maintenance Plan. The plan was further

    refined by the Air Transport Association in 1970 and re-published

    as Management Steering Group-2. The objective of MSG-1 and MSG-2

    was to develop a scheduled maintenance program to maximize safety

    and reliability at the lowest cost. MSG-2 was applied to the

    development of the DC-1O aircraft. A comparison of scheduled

    maintenance actions (overhaul) was conducted between the DC-1O and

    the DC-8. The DC-8 had been developed using the traditional

    approach while the DC-1O had the benefit of Reliability Centered

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