RELIABILITY CENTRED MAINTENANCE (RCM) Application within RCAF and Implementation in OmegaPS Mike Martin

BRIEFING OUTLINE Maintenance Environment within RCAF RCM Process (MSG-3) Principles of RCM Significant Item Selection Functional FMEA Level 1 & 2 Decision Logic Task Assignment and Packaging Implementation in OmegaPS (FRCM) OMUG 2013 M. Martin

MAINTENANCE ENVIROMENT WITHIN RCAF Maintenance Program part of Design Changes tightly regulated Conduct of Maintenance on aircraft / equipment recorded and controlled Support to Legacy fleets becoming more challenging OMUG 2013 M. Martin

WHAT IS RCM? A Definition: Primary Objectives: RCM is a structured process to identify the appropriate level of preventive maintenance for an item to: Retain inherent levels of performance, reliability and safety Minimize cost of maintenance and failures over the life cycle Primary Objectives: Ensure safety through PM actions; when PM cannot effectively ensure safety, redesign is mandatory When safety is not a concern, preserve functionality in the most economical manner with the least impact on Operations OMUG 2013 M. Martin

WHY DO RCM? New Programs: Legacy Programs: Requirement of design (ICAs) Identify APPLICABLE and EFFECTIVE scheduled maintenance tasks Initial programs conservative and generic Legacy Programs: Able to modify generic programs to suit environment and fleet performance Structured, disciplined approach to substantiating proposed Design Changes OMUG 2013 M. Martin

SAE JA1011 – Evaluation Criteria for RCM Processes FLAVOURS OF RCM ATA/MSG-3 (***) RCM II NAVAIR 00-25-403 NAVSEA S9081-AB-GIB-010 DEF STAN 02-45 Etc If any question about whether or not a process meets RCM requirements consult: SAE JA1011 – Evaluation Criteria for RCM Processes OMUG 2013 M. Martin

STEPS TO PERFORM RCM Step 1: Identify MSI Step 2: Perform Functional FMEA Step 3: Apply MSG-3 Decision Logic Level 1 – Failure Effect Code Level 2 – Task Identification Step 4: Package Maintenance Tasks OMUG 2013 M. Martin

MAINTENANCE SIGNIFICANT ITEMS (MSIs) Objective of MSI selection: select appropriate systems / components for analysis Why be selective? A/C equipment and systems have many components and parts Analysis of every component on an aircraft would be unrealistically costly and time consuming Failure of many items have no immediate impact on the a/c as a whole RCM derived maintenance program directs tasks where they matter – at Significant Items OMUG 2013 M. Martin

STEP 1 – IDENTIFY MSIs Partition equipment into major functional areas Top-down approach; identify items at highest manageable level Item is MSI if failure could: adversely effect safety Have major operational or economic consequences Be undetectable during normal operations If in doubt, item should be selected as an MSI OMUG 2013 M. Martin

PARTITION EQUIPMENT OMUG 2013 M. Martin

MSI SELECTION DECISION LOGIC OMUG 2013 M. Martin

STEP 2 - FUNCTIONAL FMEA OMUG 2013 M. Martin

RESULTS OF FMEA For each MSI: For each Function: - List of High Level Functions For each Function: - List of Functional Failures For each Functional Failure: - List of Failure Effects For each Failure Effect: - List of Components which cause this Functional Failure/Failure Effect to Occur OMUG 2013 M. Martin

EXAMPLE OF FMEA EXAMPLE ONLY OMUG 2013 M. Martin

STEP 3 – APPLY MSG-3 DECISION LOGIC LEVEL 1 – Identification of Functional failure Effect (FEC) LEVEL 2 – Identification of APPLICABLE and EFFECTIVE Preventive Maintenance Task OMUG 2013 M. Martin

MSG-3 LEVEL 1 & 2 DECISION LOGIC OMUG 2013 M. Martin

LEVEL 1 DECISION LOGIC OMUG 2013 M. Martin

LEVEL 2 DECISION LOGIC OMUG 2013 M. Martin

EXAMPLE OF LEVEL 1 / 2 EXAMPLE ONLY OMUG 2013 M. Martin

STEP 4 – TASK PACKAGING Select Significant Intervals Fit Others into this interval or multiples Group Individual Tasks Together By: Location Trade Complexity Frequency OMUG 2013 M. Martin

SAMPLE INSPECTION CARD OMUG 2013 M. Martin

TYPICAL INSPECTION Inspection Tasks (4 trades) OMUG 2013 M. Martin

CURRENT TOOLS AEPM Performa Maintenance Analyzer (ATESS) Audit ADAM data from the field Extracted into Excel files Maintenance Analyzer (ATESS) Access Database MSI FMEA Level 1 / 2 analysis Audit MS Excel OMUG 2013 M. Martin

CURRENT TOOLS Card Deck Scheduling / Planning Access Database MS Word Templates Contactor Database (IETM) ???? Scheduling / Planning MS Project / MS Excel Paper OMUG 2013 M. Martin

FUNCTIONAL RCM (FRCM) IN OmegaPS OMUG 2013 M. Martin

FRCM MODULE Create FUNCTIONAL structure MANAGE analysis assignments Perform FMEA Audit FMEA Perform Level 1 / Level 2 analysis Assign Task and Interval Audit Level 1 / Level 2 and Task analysis OMUG 2013 M. Martin

CREATE FUNCTIONAL STRUCTURE OMUG 2013 M. Martin

SELECT FUNCTIONAL RCM MODULE OMUG 2013 M. Martin

FUNCTIONAL TREE STRUCTURE OMUG 2013 M. Martin

MANAGER OMUG 2013 M. Martin

DEVELOP FMEA OMUG 2013 M. Martin

OmegaPS FMEA Worksheet OMUG 2013 M. Martin

LEVEL 1 ANALYSIS OMUG 2013 M. Martin

LEVEL 2 ANALYSIS OMUG 2013 M. Martin

LEVEL 1 / LEVEL 2 REPORT OMUG 2013 M. Martin

TASK / INTERVAL IDENTIFICATION OMUG 2013 M. Martin

POTENTIAL OmegaPS MODULE INTEGRATION PoM FRCM ANALYZER LORA PUBLISHER OMUG 2013 M. Martin

Questions? Any questions at this point?