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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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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

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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

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Failure Management Policy Condition Monitoring utilized

Output pressure monitoring

Component Washer High Pressure Pump

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