MAINTENANCE MANAGEMENT IM 503 Lecture 14: Reliability Centered M i Maintenance (RCM)

D M Dr Muhammad h d Fahad F h d Associate Professor/Director Product Development Centre Dept of Industrial & Manufacturing NED University of Engineering & Technology

Maintenance: Evolution
Profit Contributor Third Generation
Develop pment of Mainten nance

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Technical Matter Necessary ecessa y Evil First Generation

Fix it when it broke

Higher plant availability and reliability Greater safety Better product quality No damage to the environment Greater cost effectiveness

Second Generation
Higher plant availability Longer equipment life Lower costs

1940

1950

1960

1970

1980

1990 3rd Generation

2000

1st Generation
Covers period up to world war II Low level mechanization Equipment simple & over-designed d i d Low level technical skill required

2nd Generation
Mechanization increased rapidly PM techniques became popular Equipment overhaul done at t fixed fi d i interval t l Cost of maintenance increased

RCM Higher demand on plant availability Greater emphasis and laws on health, safety & environmental i t l protection

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Definition

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Reliability Centered Maintenance (RCM) is a systematic process used to determine what has to be accomplished to ensure that any physical facility is able to continuously meet its designed functions in its current operating context. RCM leads l d to t a maintenance i t program that th t focuses f preventive ti maintenance (PM) on specific failure modes likely to occur. RCM has been so named to emphasize the role that reliability theory and practice plays in properly focusing (centering) preventive maintenance activities on the retention of equipments i inherent i h d i reliability. design li bili

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Goals

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To develop design-associated priorities that can facilitate PM. To gather information useful for improving the design of items. items To develop PM-related tasks that can reinstate reliability and safety to their inherent levels in the event of equipment or system deterioration. To achieve the above goals when the total cost is minimal. minimal

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Principals

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RCM is system/equipment focused. RCM is reliability-centered. reliability centered Safety and economics drive RCM. RCM is function-oriented. Design g limitations are acknowledged g by y RCM. An unsatisfactory condition is defined as a failure by RCM.

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Questions

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Any RCM process should ensure that all of the following questions are answered effectively as per their sequence:

What are the functions and associated expected levels of the facility performance in its current operating context? How might it fail to meet its assigned functions? What are the reasons for each functional failure or failure mode? What are the effects of each failure? How does each failure matter? What remedial measures should be taken to prevent or predict each failure? What measures should be taken in the event of not finding a suitable proactive task?

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Steps p

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The basic RCM process consists of the following steps:

Identify y important p items with respect p to maintenance Obtain appropriate failure data D l fault Develop f lt tree t analysis l i d data t Apply decision logic to critical failure modes Classify maintenance requirements Implement p RCM decisions Apply sustaining-engineering on the basis of field experience

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Operation Types
Corrective Maintenance Preventive Maintenance

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RCM Components

Proactive Maintenance

Predictive Inspection / Testing

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Operation Types
Specifications for New/Rebuilt Equipment Root Cause Failure Analysis Reliability Engineering

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Age Exploration

Proactive Maintenance methods to extend equipment life

Failed Item Analysis

Recurrence Control

Rebuild Verification/ Certification

Precision Reb ild and Rebuild Installation

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Failure Mode and Effect Analysis
Failure mode and effect analysis (FMEA) is an engineering technique used to define, identify, and eliminate li i t known k and/or d/ potential t ti l problems, bl errors, and so on from the system, design, process, and/or service before they reach the customer.

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Failure Mode and Effect Analysis FMEA is a systemic methodology intended to

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Identify and recognize potential failures including their causes and effects Evaluate E l t and d prioritize i iti id tifi d failure identified f il modes d since i failures are not created equal Identify and suggest actions that can eliminate or reduce the chance of the potential failures from occurring

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Failure Mode and Effect Analysis

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Ideally, FMEAs are conducted in the product design or process development stages. However, conducting them on existing products and processes may also yield benefits such as in RCM to develop an effective preventive maintenance program. Identifying known and potential failure modes is an important task in FMEA.

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Failure Mode and Effect Analysis

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Using data and knowledge of the process or product, each potential failure mode and effect is rated in each of the following three factors: Severity: the consequence of the failure when it happens Occurrence: the probability or frequency of the failure occurring Detection: the probability of the failure being detected before the impact of the effect is realized

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Failure Mode and Effect Analysis

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Then these three factors are combined in one number called the risk priority number (RPN) to reflect the priority of the failure modes identified.

Failure Mode

Effects
(Severity) S

Causes
(Occurrence) O

Control
(Detection) D

Priority
RPN =SxOxD

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Failure Mode and Effect Analysis

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Process

Select a high-risk process. Review the process. Brainstorm potential failure modes. Identify the root causes of failure modes. List potential effects of each failure mode. Assign severity, occurrence, and detection ratings for each effect. C l l Calculate the h risk i k priority i i number b (RPN) for f each h effect. ff Prioritize the failure modes for action using RPN. Take action to eliminate or reduce the high-risk failure modes. Calculate the Resulting RPN as the failure modes are reduced or eliminated as a mean of monitoring the redesigned improved product or process.

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Failure Mode and Effect Analysis

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Standards

MIL-STD-1629A (1984) BS 5760 (1991) BS EN 60812 (IEC 60812) 2006

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Failure Mode and Effect Analysis

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Severity Rating Scale

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Failure Mode and Effect Analysis

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Occurrence Rating Scale

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Failure Mode and Effect Analysis

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Detection Rating Scale

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Failure Mode and Effect Analysis

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Detection Rating Scale

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Failure Mode and Effect Analysis

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Severity Rating Scale

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Failure Mode and Effect Analysis

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Occurrence Rating Scale

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Failure Mode and Effect Analysis

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Deficiencies of RPN
Gaps in the ranges: 88% of the range is empty, only 120 of 1000 numbers are generated Duplicate RPNs: for several combinations where different factors lead to the same RPN N Sensitivity to small changes: a small change in one factor has a much larger effect when the other factors are larger than when they are small (example: 9x9x3 = 243, 243 and 9x9x4 =324 versus 3x4x3 = 36 and 3x4x4=48) Inadequate scaling: the ratios on occurrence table are not proportional or linear; e.g. the ratio can be 2, 2.5 or 5 between the two consecutive ratings

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Failure Mode and Effect Analysis

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Deficiencies of RPN
Inadequate scale of RPN.

The differences in RPN number might appear negligible while in fact significant. An example would be: the values: S = 6, O = 4, D = 2, would produce an RPN = 48, while S = 6, O = 5, and D = 2 would produce RPN = 60. The second RPN is not twice the first number, while in fact O = 5 is twice the probability of occurrence with O = 4. Therefore the RPN numbers should not be compared linearly.

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Measurement Indicators

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Equipment Availability

H ea EA = TH rp
H ea = Number of hours each unit of equipment is available to run at capacity

TH rp = Total number of hours during the reporting period

Th benchmark The b h k fi figure f for this hi metric i i is 96%

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Measurement Indicators

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Emergency Percentage Index

EP =

H ejj TH w

H ej = Total T l number b of f hours h worked k d on emergency jobs j b

TH w = Total number of hours worked

The benchmark figure for this metric is 10% or Less

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Measurement Indicators

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Maintenance Overtime Percentage Index

Pmo

TMOH = TRMH

TMOH = Total number of maintenance overtime hours during period TRMH = Total number of regular maintenance hours during period

Th benchmark The b h k fi figure f for this hi metric i i is 5% or L Less

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Measurement Indicators

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Preventive Maintenance Index

Ppm

MHPP = MHR + MHPP

MHPP = Total man hours of PM work

MHR = Total man hours of reactive maintenance work

Th benchmark The b h k fi figure f for this hi metric i i is 70%

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Measurement Indicators

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Reactive Maintenance Index

Prm

MHR = MHR + MHPP

MHPP = Total man hours of PM work

MHR = Total man hours of reactive maintenance work

Th benchmark The b h k fi figure f for this hi metric i i is 30%

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Benefits

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Improvement in product quality Improvement in useful life of products Improvement in safety/environmental protection Development of a maintenance database I Improvement t in i maintenance i t cost t effectiveness ff ti Higher plant availability and reliability

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Problems

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The application was superfluous or hurried Computers were used to drive the process Only one individual was assigned to apply RCM Only maintenance department on its own applied RCM M f t Manufacturers/vendors / d were asked k d to t apply l RCM on their th i own.