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    Reliability Centered Maintenance

    June 9, 2011

    Gary MartiniFord Motor Company

    Global Powertrain Manufacturing Engineering

    Systems Reliability and Maintainability Supervisor

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    Originating Author: G. Martini 01/07/2011 PTME Powertrain Template_Maintenance System_010720112

    Reliability Centered Maintenance

    What is Reliability Centered Maintenance?

    RCM History

    RCM Specifications

    Maintenance Strategies

    RCM Steps

    Next Steps-Opportunities

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    Originating Author: G. Martini 01/07/2011 PTME Powertrain Template_Maintenance System_010720113

    RCM is a process to determine what must be

    done to ensure that a physical asset continues

    to do what its users want it to do

    RCM focuses on reducing failure consequences,

    via a Risk Management Tool

    without compromising safety or operating

    capability Standard maintenance decision logic

    Reliability Centered Maintenance

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    Originating Author: G. Martini 01/07/2011 PTME Powertrain Template_Maintenance System_010720114

    RCM was started in the airline industry becausetraditional methods based on preventing asset

    deterioration rather than minimizing failure

    consequences were too costly and not effective (1965)

    As the RCM process was adopted by other industries,

    it was streamlined and simplified

    The foundation for modern RCM was published in the

    book Reliability-Centered Maintenance, Second Editionby John Moubray (1992)

    SAE JA1011 & JA1012 standardized latest RCM

    (1998)

    RCM History

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    Different RCM Specifications

    SAE J1011 Society of Automotive Engineers, Evaluation Criteria

    for RCM Processes

    SAE J1012 Society of Automotive Engineers, Guide to the RCMStandard

    A066-579 Nowlan and Heap, Reliability Centered Maintenance

    MIL-STD-2173 Reliability Centered Maintenance Requirements forNaval Aircraft, Weapons Systems, and SupportEquipment

    NAVAIR 00-25-403 Naval Air Systems Command, Guideline for NavalAviation Reliability Centered Maintenance Process

    Moubray, John, Reliability Centered Maintenance 2

    ATA MSG-3 Air Transport Association ofAmerica,OperatorManufacturer Scheduled Maintenance Development

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    Originating Author: G. Martini 01/07/2011 PTME Powertrain Template_Maintenance System_010720116

    Functional

    Failure CostsPM Costs

    The Maintenance Sweet Spot

    While there is a theoretical optimal PM level that minimizes cost, in the real world

    there are both too many and too few PMs being performed in a plant.

    Number of PMs

    Net Cost

    Economically

    Optimal PM level

    6

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    Maintenance Strategies

    Looks for unsatisfactory

    conditions

    An acceptable strategy

    Minimizes unsatisfactory

    conditions

    Looks for already

    failed conditions

    Eliminates unsatisfactory

    conditions

    7

    Maintenance

    Predictive/ Condition

    Monitoring

    Preventative/ Restorative

    Failure Finding

    Redesign

    Run to Failure

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    The RCM Process consists of 4 Major Steps

    1. Set Asset Priorities

    2. Identify asset functions, performance standards, and

    functional failures, failure mode and failure effects &

    consequences

    3. Failure mode risk analysis

    4. Failure management policies

    Reliability Centered Maintenance

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    Step 1. Set Asset Priorities

    First Application Assets (new machines)

    Assets with historically high maintenance

    Assets based on operational criticality (i.e. single path)

    Assets with high multiples

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    Step 2. Component Washer Pump Example

    1) Performance Standards - What are the

    functions and associated desired standards of

    performance of the asset in its present

    operating context (functions)?

    2) Sub-system Functional Failure -

    In what ways can it fail to fulfill its

    functions (functional failures)?

    Provide washer fluid at 3,500 psi pressure

    and xx GPM flow for each application

    Pressure and flow out of

    specification limits

    Sub-systems/

    Components

    Top section of

    high pressurepump

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    Step 2. Component Washer Pump Example

    3) Cause- What causes

    each functional failure

    (failure modes)?

    4) Effect- What happens

    when each failure occurs

    (failure effects)?

    5) Consequence- In what way

    does each failure matter

    (failure consequences)?

    Risk

    Assessment

    (R/Y/G)

    Labyrinth seal wear

    (life limitedcomponent)

    Machine alarms and

    stops

    8 hrs of Downtime, $ repair

    costs

    Yellow

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    Step 3. Risk Management Decision

    This filter speeds analysis:Eliminates unnecessary analysis

    Helps team make faster choices

    7 6 5 4 3 2 1

    ConsequenceScore Asset Downtime

    1 more than 8 hours

    2 4 to 8 hours

    3 1 to 4 hours

    4 30 min to 1 hour

    5 10 - 30 min

    6 < 10 min

    7 1 cycle

    Score Likelihood

    1 > 1 inanhour

    2 1 ina shift

    3 1 in a day

    4 1 in a week

    5 1 in a month

    6 1 in3 months

    7 1 in6 months

    8 1 in a year

    9 1 in2 years

    10

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    Failure Management Policy Condition Monitoring utilized

    Output pressure monitoring

    Component Washer High Pressure Pump

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