reliability centered maintenance made simple

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  • 1. RCMBlitzTM RCM Made SimpleIntroduction to RCM BlitzPresented by:Doug PlucknetteWorld-Wide RCM Discipline LeaderWhat would you do with morefree time?GPAlliedCopyright 2008 Allied Reliability, Inc.

2. RCMBlitzTM Welcome to our RCM Blitz!When it comes to building a complete maintenancestrategy that will achieve and maintain the inherentdesigned reliability of an asset, there is no other toolavailable that has the success record of traditional RCM.Doug PlucknetteReliability Centered MaintenanceUsing RCM BlitzCopyright 2008 Allied Reliability, Inc. 3. RCMBlitzTMSpecific Benefits of Applying the RCM toYour ProcessYPYour Company will be able to develop acomplete maintenance strategy for yourequipment that includes clearly written andprecise preventive and predictivemaintenance tasksYour Company will be able to put into placefailure-finding tasks that will reduce thegprobability of catastrophic HSE (Health,Safety, Environmental) failures Copyright 2008 Allied Reliability, Inc. 4. RCMBlitzTMSpecific Benefits of Applying the RCMMethod to Your Process, contdM th d t YPtdYour Company will learn how to reduce MTTR(Mean Time To Restore) through the use ofConsequence Reduction TasksYour Company will be able to determine thespare parts that need to be stored on siteand the parts that can stored by a vendorYour Company will learn how to identify whereto apply the RCM Blitz process based onpp y pReliability MeasuresCopyright 2008 Allied Reliability, Inc. 5. RCMBlitzTMSpecific Benefits of Applying the RCMMethod to Your Process, contdM th d t YPtd Reduce Emergency/Demand maintenance work Reduce maintenance costs by reducingsecondary equipment damage Reduce unit cost of product by loweringmaintenance costs and improving OverallEquipment Effectiveness (OEE)q p() Increase the understanding of how yourequipment is supposed to work for bothoperations and maintenance peopletid i tlCopyright 2008 Allied Reliability, Inc. 6. RCMBlitzTMSpecific Benefits of Applying the RCMMethod to Your Process, contdM th d t YPtdDevelop a detailed and effectivetroubleshooting guide based on actual failurealarms, effects and symptomsDevelop detailed operations checklists toensure proper set-up and operation ofequipment - (What would the reliability of theairline industry be without checklists?)Learn how to apply the RCM process to newpp ypequipment designs Copyright 2008 Allied Reliability, Inc. 7. RCMBlitzTMWhy Does the RCM Method Work? RCM adds the right amount of structure and disciplineto the expert knowledge of your people The finished product is a complete maintenancestrategy based on predicting, preventing andeliminating specific Failure Modes The airline industry has a proven record of reliabilityand safety yet their maintenance cost per replacementvalue is lower than most manufacturing maintenance l i l tht f t i i t The big difference is leadership, structure anddisciplineCopyright 2008 Allied Reliability, Inc. 8. RCMBlitzTMSection 1 RCM HistoryRCMBlitzTMWhat would you do with morefree time?Copyright 2008 Allied Reliability, Inc. 9. RCMBlitzTMThe History of RCM US DOD and United Airlines Utilities Industry Manufacturing Commercial Standards for RCM SAE J1011 PASS55Copyright 2008 Allied Reliability, Inc. 10. RCMBlitzTMVarious Approaches to RCM Traditional SAE J1011 7 Steps p Streamlined PMO Copyright 2008 Allied Reliability, Inc. 11. RCMBlitzTMSection 4 RCM MaintenanceSt ateg esStrategiesRCMBlitzTMWhat would you do with morefree time?Copyright 2008 Allied Reliability, Inc. 12. RCMBlitzTMMaintenance Tasks The key to ensuring the designed reliabilityof your process is selecting the correct y gmaintenance task to address a specificfailure mode or cause of failureCopyright 2008 Allied Reliability, Inc. 13. RCMBlitzTMMaintenance Tasks, contdIn RCM we have 5 types of maintenance tasks1. On-condition Maintenance2.2Preventive Maintenance3. Failure Finding4.4Redesign5. Run to Failure Copyright 2008 Allied Reliability, Inc. 14. RCMBlitzTMOn-Condition MaintenanceA maintenance task that is put into place todetect failure resistance to a specific failuremodeThe detection of failure is based on a knownpotential failure conditionCopyright 2008 Allied Reliability, Inc. 15. RCMBlitzTMTraditional Types of On-ConditionMaintenanceM i t Vibration Analysis ThermographygUltrasonic Testing Tribology gNon-Destructive Testing Motor Current Analysis Process Verification Copyright 2008 Allied Reliability, Inc. 16. RCMBlitzTMNon-Traditional Types of On-ConditionMaintenanceM i t Human SensesCopyright 2008 Allied Reliability, Inc. 17. RCMBlitzTMHow PdM Works Early Identification ofDefectsD f tPFCopyright 2008 Allied Reliability, Inc. 18. RCMBlitzTMCompleting the P-F Curve RCM Reliability Centered Maintenance Precision Alignment FMEA Precision Balancing Design RCM Blitz Installation Standards Five Rights of Reliability Torque Specifications Precision Tools Select S S l t Supplier Agreements li A t Requirements Documents Design StandardsReactiveProactive Maintenance/Reliability Tasks PdM TasksMaintenance sistance to Failure I Installationt P Potential Failure F Functional Res I-P Interval Failure P-F IntervalT - Time The Modified P-F Curve and I-P Interval are intellectual property of Reliability Solutions, Inc. (Patent Pending) Copyright 2008 Allied Reliability, Inc. 19. RCMBlitzTMPreventive Maintenance (PM) Tasks Preventive maintenance is time based, it isperformed on equipment that has a knownage or useful lifef l lif These tasks should be set up to preventfailures on components that fit age basedfailure patterns (A-C) Scheduled Inspection, Scheduled Rework p ,and Scheduled Discard are preventivemaintenance tasks Copyright 2008 Allied Reliability, Inc. 20. RCMBlitzTMFailure Finding TasksScheduled inspections of a hidden functionitem, intended to find functional failures thathave already occurred but are not evident tothe operating crewThe objective of a failure finding task is toensure adequate availability of a hiddenfunctionCopyright 2008 Allied Reliability, Inc. 21. RCMBlitzTMRedesignAny change in equipment, process, orproceduresIn order for a redesign to be consideredapplicable and effective it must: Eliminate the failure Be cost effective Reduce the conditional probability of failure to anacceptable level Change the function of an item from hidden toevident Copyright 2008 Allied Reliability, Inc. 22. RCMBlitzTMNo Scheduled MaintenanceThis becomes the maintenance strategywhen there is no applicable or effective task,or no applicable or effective redesign*When No Scheduled Maintenance is yourmaintenance strategy, you must put in place aconsequence reduction strategyCopyright 2008 Allied Reliability, Inc. 23. RCMBlitzTMConsequence Reduction StrategyWhen no schedule maintenance is the onlyremaining strategy, it becomes important tog gymake sure you have the proper spare parts,resources and procedures in place to reducetheth consequence of th failure f the f il Copyright 2008 Allied Reliability, Inc. 24. RCMBlitzTMPulling It All TogetherSo how is all of this accomplished? Apply the RCMBlitz process to your equipment!Copyright 2008 Allied Reliability, Inc. 25. RCMBlitzTMSection 5 The RCM ProcessRCMBlitzTMWhat would you do with morefree time?Copyright 2008 Allied Reliability, Inc. 26. RCMBlitzTMThe 7 Steps of Reliability Centered MaintenanceTraditional RCM Methodologies fit this 7-step process defined bySAE standard JA1011:1. What are the functions of the asset?2. In what way can the asset fail to fulfill its functions?3. What causes each functional failure?4. What happens when each failure occurs?5. What are the consequences of each failure?6. What should be done to prevent or predict the failure?7. What should be done if a suitable proactive task cannot be found? Copyright 2008 Allied Reliability, Inc. 27. RCMBlitzTMThe RCM Process1. List the Process Functions2. List the Functional Failures3. List the Failure Modes and Probability of Failure4. Describe the Failure Effects5. Determine Consequence Category6. Run the Failure Mode through the RCM Decision Process7. Select a Maintenance Task and assess spare partsp p Copyright 2008 Allied Reliability, Inc. 28. RCMBlitzTMListing Functions Function The normal or characteristic actions of an item, defined in terms of performance capabilities Point at which you actually begin your RCM analysis Listing the system and component functions is a key step in the RCM processypp The first function we list will be the System Function or Main Function The System Function will clearly state what the intent of the process is, and the performance standards it is expected to maintain p Copyright 2008 Allied Reliability, Inc. 29. RCMBlitzTMMain FunctionThe Main Function or System FunctionThe reason the asset or process exists including p gthe expectation of the process and performancestandards we need to maintainExample Main Function If you were about to analyze a process that made #2pencils, your main function would be:1.To b bl to1 T be able t make #2 pencils at a rate of 1200 units perkil tt f ithour, while meeting all quality, safety, health, andenvironmental standards Copyright 2008 Allied Reliability, Inc. 30. RCMBlitzTMMain Function, contd Once you have listed the Main Function anddetermined the performance standards, youywill move on to list all of the supportfunctions Copyright 2008 Allied Reliability, Inc. 31. RCMBlitzTMSupport FunctionsDescribe the functionality of each component withinthe system The support function for fuel piping would be: To be able to contain and transport fuel The support function for a gear box would be: To be able to reduce RPM by a 4 to 1 ratio The support function for a E-Stop button would be: To be capable of shutting down the system in the eventof an emergency A support function for equipment structure would be: To be able to support the vesselCopyright 2008 Allied Reliability, Inc. 32. RCMBlitzTMHidd


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