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Reliability Centered Maintenance Analysis
Lesson 8 Reliability Centered Maintenance Analysis
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Topic 1: Introduction What’s in it for me?
Reliability Centered Maintenance (RCM) Analysis is a structured framework for analyzing a system’s functions and potential failure modes to develop a scheduled maintenance plan, balancing availability and risk in an efficient and cost-effective manner. RCM uses information identified in the Failure Mode Effects and Criticality Analysis (FMECA) and Fault Tree Analysis (FTA) to define and balance “Condition-based”, “Interval-based”, and “Run-To-Failure” maintenance requirements. The process results the incorporation of revised preventive and corrective maintenance tasks/instructions and frequencies in the Maintenance Task Analysis (MTA). RCM Analysis combines both engineering and sustainment requirements and perspectives to improve availability, reduce the need for maintenance, and lower costs.
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Technology Maturation & Risk Reduction
Life Cycle Management Framework Where Are You? What Influence Do You Have? Technology Maturation & Risk Reduction RCM Analysis bridges Reliability Engineering and maintenance, and is updated iteratively with data maturity. Adapted from GEIA-HB-0007
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RCM Analysis Lesson Approach
This lesson approach will emphasize the analytical process undertaken to determine maintenance planning, for which the LCL will play the role of reviewer. Build an RCM Analysis plan and define and gather data inputs Determine applicable and effective maintenance task candidates and frequencies Report findings to IPT and package tasks for input into the Maintenance Task Analysis activity.
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TLO: Examine Reliability Centered Maintenance (RCM) Analysis processes and contribution to Supportability and Supportability Analysis Topic Objectives Topic 1: Introduction Welcome Where Are You? What Influence Do You Have? Topic 2: Overview of RCM Analysis Analyze the impact of Reliability Centered Maintenance (RCM) Analysis on Supportability and Supportability Analysis. Topic 3: Set Up – Building a Plan and Gathering Inputs Examine RCM Analysis planning considerations, analysis tools, and data inputs. Topic 4: Analysis – Determining Maintenance Tasks and Intervals Examine the RCM analytical process and its steps. Analyze failure maintenance strategy options resulting from RCM Analysis. Relate RCM to the Condition Based Maintenance Plus (CBM+) process. Examine diagnostic, prognostic, and health management capabilities in the CBM+ process and their impact on Supportability and Supportability Analysis. Topic 5: Report Findings – Data Management and Communication Paths Examine reporting requirements and communication paths for managing RCM Analysis results. Topic 6: Exercise and Simulation Find and validate applicable inputs from previous analyses Given a specific failure mode, determine the most applicable and effective failure maintenance strategies and intervals. Topic 7: Summary
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Topic 2: Overview of RCM Analysis
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System Functioning at Intended Level
What is RCM Analysis? RCM Analysis identifies maintenance tasks and task intervals to mitigate critical failure consequences and ensure a system’s inherent Reliability. On-Condition & Interval-based Tasks Servicing/Lubrication Tasks Hard Time Remove/Replace Failure Findings Inspections Proactive Maintenance Maintenance Before Failure Logistician Terms Preventive System Functioning at Intended Level Reactive Maintenance Repair After Failure Other Logical Actions Corrective Redesign, Change Training and Processes Run-to-Failure RCM Analysis Terms
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What is RCM Analysis? Significant Functions
Only systems or components with functional significance undergo RCM Analysis. Function Does the loss of function have an adverse effect on safety or environment? Yes No Does the loss of function have an adverse effect on operations? Yes One or more must apply No Does the loss of function have an adverse economic impact? Yes No Proceed with RCM Analysis Is the function protected by an existing PM task? Yes No Non-Significant Functions Significant Functions Corrective Maintenance
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What is RCM Analysis? Inputs & Influence
RCM conforms to a larger framework of Supportability analyses, working through MTA to identify and refine maintenance tasks. R&M Sub-set of R&M FMECA/FTA Influence Design Influence Support Refine Supportability Analyses Significant Failures RCM Analysis Non-Significant Failures Corrective Tasks Corrective Tasks PM Tasks & Intervals MTA Corrective & Hard Time Tasks, Intervals, New MTBF LORA
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What is RCM Analysis? ASOE Model
The ASOE model has four distinct intersections representing program performance and Sustainment objectives. Balancing these priorities require a series of trade-off analyses. Technical Performance Supportability Process Efficiency Life Cycle Cost Functions Reliability Production Total Ownership Cost Capabilities Maintainability Maintenance Support Features Logistics Operations Design Affordability Design Effectiveness Mission Effectiveness Affordable Systems Operational Effectiveness
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ASOE Trade-off Reliability vs. Maintenance
During RCM Analysis, Reliability and maintenance tradeoff to produce efficient and effective maintenance tasks at the best cost. Technical Performance Functions Capabilities Technical Performance Functions Capabilities Supportability Reliability Maintainability Support Features Supportability Reliability Maintainability Support Features Life Cycle Cost Total Ownership Cost Process Efficiency Production Maintenance Logistics Operations Process Efficiency Production Maintenance Logistics Operations
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What is RCM Analysis? Inputs and Outputs
Design Characteristics System Configuration Developmental Testing Results Built-in-Tests (BIT) Accessibility, Modularity, Testability Human Systems Integration Maintenance Data Systems Cost Data Logistics Product Database Reliability Analyses Maintainability Analyses Inputs FMECA/FTA FRACAS from T&E events and field failure/repairs Reliability Centered Maintenance Analysis Process Recommend Create/Refine Update/Add New Tasks & Frequencies RCM Analysis Report Preventive Maintenance Tasks & Intervals Corrective Maintenance Tasks Other Actions (e.g., redesign, training) Life-Cycle Sustainment Plan Outputs Maintenance Plan MTA Revised MTBF
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Topic 3: Set Up – Building a Plan and Gathering Inputs
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Collect/Load Data Inputs
Set Up 1.1 1.2 1.3 Build Plan Select RCM Analysis Tool Define RCM Data Inputs 1 Iterate Plan Collect/Load Data Inputs Our planning considers three main areas: 1.1 Build Plan – Defines RCM Analysis plan and execution strategy: Milestone events, required deliverables, plan for Sustainment, and responsibilities. 1.2 Select RCM Analysis Tool – GEIA-STD compliant LPD enables import/export into analytical tools external to the database. 1.3 Define RCM Data Inputs – Given failure characteristics, determine appropriate inputs for maintenance task selection.
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Build a Plan Process and Data Management
Planning encompasses all RCM Analysis activities and their iterations, from initial scoping to Sustainment. RCM Analysis Process Flow T&E and Operational Data Set Up SAE GEIA-STD-0007 Data 1 RCM Tool Data Import / Template 2 Plan Considers: Needs/Constraints IPT Responsibilities Analysis Activities Reporting & Data Management Sustainment Implications Maintenance Plan MTA Maintenance Tasks and Frequencies 3 Field Data Reliability Approved Analysis 5 RCM Analysis Report 6 4 Trade-offs Recommended Maintenance Tasks, Intervals, Other Actions Report Findings
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T&E and Operational Data
Determine Data Inputs After selecting a SAE GEIA-STD-compliant analysis tool, Logistics Product Data (LPD) are identified and imported into the tool for analysis. Set Up GEIA-STD-0007 Data 1 RCM Tool Data Import / Template 2 T&E on failure management and operational data are reported through FRACAS, which is the vehicle for data into RCM. T&E and Operational Data Data Inputs Design characteristics System configuration Developmental testing Subject matter experts Reliability analyses Maintainability analyses FMECA/FTA Human systems integrations Maintenance data systems Cost data FRACAS Tool Functionality Data management and reporting FMEA/FMECA Maintenance tasks selection Optimal interval calculation Cost comparisons
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Topic 4: Analysis – Determining Maintenance Tasks and Intervals
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Categorize Failure Consequences Determine Maintenance Tasks/Intervals
Analysis Our analysis consists of two main areas: 2.1 Categorize Failure Consequences – Identify if evident/hidden failures impact safety, environment, operation, or economics. 2.2 Identify Maintenance Tasks and Task Intervals – Determine preventive, corrective, and other maintenance actions to mitigate risk of failure; recommend frequencies and intervals to perform preventive maintenance. 2 2.1 2.2 Categorize Failure Consequences Determine Maintenance Tasks/Intervals Iterative Analysis
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RCM Analysis Process Map
T&E, Field Data MTA RCM Analysis RCM Analysis matches failure modes with maintenance tasks that are both applicable and effective. No Significant Function? 8.1 8.2 8.3 8.4 8.5 8.6 FMECA – Determine Failure Mode Criticality Categorize Failure Consequences Yes Categorize Failures by Type of Impact Does the task address failure characteristics? How effectively does the task reduce failure effects? Identify On-Condition Tasks/Intervals Identify Interval-Based Tasks/Intervals Determine Maintenance Tasks and Task Intervals Identify Run-to-Failure Tasks Trade-offs occur between Reliability, Maintainability, and cost. Data updates drive refinement of maintenance approach. Identify Other Logical Actions Feedback
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RCM Analysis Decision Diagram
The RCM decision diagram is a comprehensive look at the choices involved in narrowing task selection. Evident Functional Failure Hidden Functional Failure Yes No Is functional failure evident during normal use? A 1 Adverse Effect on Operating Capability? Direct & Hazardous Effect? No 2 3 Yes Tasks desirable if risk is reduced to an acceptable level Operational Effects: 5 Tasks desirable if cost is less than repair costs Economic Effects: 6 4 Yes No Operational Effects: Tasks required to avoid hazardous effects
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Categorizing Consequences Justifying Preventive Maintenance
Safety consequences require preventive maintenance (PM); otherwise, selection of a PM task is driven by cost. Impact on Safety/Environment Categorize Failures by Type of Impact FMECA – Determine Failure Mode Criticality RCM Analysis Categorize Failure Consequences Significant Function? No Yes MTA T&E, Field Data Requires preventive maintenance. PM task must reduce probability of failure to acceptable level. Impact on Operational Capability Economic Impact Only Cost of implementation of PM task is less than cost of running to failure. Impact on mission exists. Cost of PM must be less than cost of repair plus cost of mission loss. No impact on mission capability. Economic consequence only. Cost of PM must be less than cost of repair.
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On-Condition Maintenance Predictive Maintenance
On-condition maintenance compares performance against known criteria to determine when maintenance is required, based on actual equipment condition. Identify On-Condition Tasks/Intervals Identify Interval-Based Tasks/Intervals Identify Run-to-Failure Tasks Determine Maintenance Tasks and Task Intervals Identify Other Logical Actions Healthy Range Performance outside healthy range indicates potential failure Opportunity for maintenance, if required. Example: Measure the tread on your tire!
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On-Condition Maintenance The P-to-F Curve
Inspections occur between the time a potential failure (PF) condition first appears and complete functional failure (FF). Applicability Possible to define potential failure (PF) characteristics Possible to detect potential failure with specific tasks Consistent and sufficient PF interval Multiple failure conditions are possible. Intervals Intervals determined based on: Consequences of failure Effectiveness of task Accessibility of item Skill of personnel performing inspection Industry standards Specific system requirements Opportunity for inspections Inspection methods include human inspection and sophisticated monitoring equipment, such as built-in sensors.
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On-Condition Maintenance CBM+ and Prognostics & Health Management (PHM)
CBM+ optimizes on-condition maintenance through a comprehensive set of tools, technology, and processes that provide more accurate condition data and failure predictions. Diagnostic Capabilities What is the component’s current condition and ability to perform its function? Hardware Software Design Processes Tools Communications Prognostic Capabilities What future failures might occur and when? What is the component’s remaining useful life? Health Management Systems: Integrated information systems track, and analyze diagnostic/prognostic data to facilitate appropriate logistical actions.
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CBM+ and PHM Impact on Supportability
Conducting maintenance based on accurate and timely condition data contributes directly to improved mission effectiveness. Improves Operational Availability Improves maintenance effectiveness Reduces Mean Down Time Reduces overall logistical footprint Reduces life cycle ownership costs
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Interval-based Tasks Overview
Interval-based maintenance tasks are scheduled regardless of actual equipment condition. Applicability Consumable Subject to wear out Demonstrate a known failure pattern Identify On-Condition Tasks/Intervals Identify Interval-based Tasks/Intervals Identify Run-to-Failure Tasks Determine Maintenance Tasks and Task Intervals Identify Other Logical Actions Types of Interval-based Tasks Servicing/Lubrication Hard Time Remove/Replace Failure Findings Inspections Examples: Inspection Adjustments Cleaning Lubrication Parts replacement Calibration Repair
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Interval-based Tasks Overview
Interval-based maintenance tasks are scheduled regardless of actual equipment condition. Identify On-Condition Tasks/Intervals Identify Interval-Based Tasks/Intervals Identify Run-to-Failure Tasks Determine Maintenance Tasks and Task Intervals Identify Other Logical Actions
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Servicing/Lubrication Tasks Interval-based Maintenance
Servicing and lubrication tasks are not the result of a specific failure, but are part of normal maintenance schedules for an item. Servicing Replenishes consumables expended during normal operational use, such as fuel. Lubrication Protects against friction and wear. Applicability Required by system design or operational need Applicability Non-permanent lubrication requiring replenishment Intervals Scheduled according to need Intervals Scheduled based on life of lubricant, usage, operational environment
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Hard Time Remove/Replace Interval-based Maintenance
Hard time maintenance tasks remove a component for repair or replacement at a predetermined age, regardless of equipment condition. Applicability Item can survive to useful life Known wear-out age On-condition inspection not applicable Point where probability of failure less than requirement Safe Life Limit Maximizes useful life Economic Life Limit Intervals Safety consequences determine interval: Safe Life Limit: Point below which no failure can occur Economic Life Limit: Point when cost is less than/same as run-to-failure Reliability requirement Unreliability Age Wear Out
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Hard Time Remove/Replace Water Pump Example
Requirement: A car’s water pump must meet a minimum Reliability of 85% over a 96,000 kilometer interval. This kind of Reliability graph is called a Weibull curve, and it is constructed from test data to predict future events. 85% Reliability, 96k km 78% Reliability, 100k km Reliability 20% Reliability, 104.5k km 0% Reliability, 110k km
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Economic Remove/Replace Water Pump Example
Requirement: Using a cost per distance graph, determine the most economical replacement time. Water Pump Cost/1000Km 100,000 kilometer is most economical, but below the 85% Reliability requirement
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Hard Time Remove/Replace Water Pump Example
Hard time maintenance tasks remove a component for repair or replacement at a predetermined point in time, cycles ,or mileage, regardless of equipment condition. Unreliability Economic Life Limit Safe Life Limit Wear Out
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Failure Finding Inspections Interval-Based Maintenance
Hidden failures not noticeable to operator during normal operations require regular failure finding inspections. Examples Back-up systems Protective systems Circuit breakers Relief valves Applicability Failure not known to operator during normal use Built-in redundancy Critical situation should a secondary failure occur Intervals Pre-/post-mission inspections checklist Evident Failure Hidden Failures Operator identifies failure during normal operating procedures. Requires actions outside normal operations to detect failure
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Run-to-Failure Corrective Maintenance
A run-to-failure task allows the failure to happen, with no preceding preventive maintenance. This type of failure is unscheduled and therefore carries costs beyond just repair. Applicability Non-critical failure Unlikely failure Consequences of failure are acceptable Redundancy exists Small items Identify On-Condition Tasks/Intervals Identify Interval-Based Tasks/Intervals Identify Run-to-Failure Tasks Determine Maintenance Tasks and Task Intervals Identify Other Logical Actions Costs Item repair Secondary damage Multiple failures Loss of operations
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Run-to-Failure Water Pump Example
The water pump is NOT a good candidate for run-to-failure. Its failure can cause secondary damage to other engine components and is likely to occur after its 96,000 km scheduled removal cycle. Economic Life Limit Safe Life Limit Run To Failure Wear Out
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Determine Maintenance Tasks and Task Intervals
Other Logical Actions Other actions outside of maintenance tasks may be required to reduce the risk of failure to an acceptable level. Identify On-Condition Tasks/Intervals Identify Interval-Based Tasks/Intervals Identify Run-to-Failure Tasks Determine Maintenance Tasks and Task Intervals Identify Other Logical Actions Applicability When run-to-failure is not an option, but preventive maintenance is not applicable Positive ROI on Availability and cost Reduced impact of failure Examples Redesign Change to procedures Change to training Change in technical manuals Change to emergency procedures Additional data collection and analyses
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Topic 5: Report Findings – Data Management and Communication Paths
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Package Tasks into Initial Maintenance Plan
Report Findings Our analysis findings fall into three broad categories: 3.1 Run RCM Report – Run report summarizing significant functions, functional failure analysis (FMECA), and maintenance task selections/intervals. Package Tasks into Initial Maintenance Plan – Bundle tasks, frequencies, and intervals into work packages for adoption into the MTA process. 3.1 3.2 3.3 3 Run RCM Report Package Tasks into Initial Maintenance Plan Update MTA Recommendations
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Report & Implement Findings
RCM Analysis Report Findings: List of significant items by effect category FMECA results Evident vs. hidden failures Maintenance task summary with task selection and interval for each failure SAE GEIA-STD-0007 Data 1 Tasks are packaged for input into MTA, where the LCL updates the LPD. MTA Recommendations submitted to IPT for approval. Approved 6 5 RCM Analysis Report Recommended Maintenance Tasks, Intervals, Other Actions Trade-offs 4 Report Findings
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RCM Analysis Report The RCM Analysis report summarizes the functional failure analysis and maintenance task selections. Exercise and Simulation: You’ll be completing the RCM Analysis report for the Strike Talon’s R/T Cooling Assembly.
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Map Failure Modes to Tasks
The failure modes identified in the RCM Analysis eventually translate into preventive tasks in the Logistics Product Database.
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Inspect UAV SATCOM Control Task
CAUTION INSPECT INSPECT
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RCM Analysis Results IPT Communication Paths
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Topic 6: Exercise and Simulation
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What maintenance tasks are appropriate to perform on the fans in order to meet Reliability requirements for the Aux Cooling Assembly? Exercise: Identify data inputs to conduct RCM Analysis. Simulation: Using data inputs: Part 1: Conduct RCM Analysis on the fans to determine the most appropriate and effective maintenance tasks Part 2: For the selected tasks, determine the appropriate frequency
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10 minutes Group grade Identify data inputs to conduct RCM Analysis
In Blackboard, select the Lesson 8: Exercise link in the lesson folder.
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Using data inputs, conduct RCM Analysis on the fans to determine the most appropriate and effective maintenance tasks and frequencies. 30 minutes Not graded In Blackboard, select the Lesson 8: Simulation Part 1 link in the lesson folder.
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Topic 7: Summary
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System Functioning at Intended Level
RCM Analysis impacts design effectiveness, mission effectiveness, and design Affordability. RCM Analysis: Spans the larger framework of R&M, FMECA, MTA, and LORA analyses. Determines maintenance tasks and frequencies for critical failures identified by the FMECA and FTA. Outcomes serve as input to Maintenance Task Analysis (MTA). The MTA is the authoritative analysis that consolidates all other analyses that impact maintenance tasks. Uses FRACAS as a primary input: Failure reporting, analysis, and corrective actions based on CBM, T&E, and field data. System Functioning at Intended Level
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TLO: Analyze Reliability Centered Maintenance (RCM) analysis processes and contribution to Supportability and Supportability Analysis (Case Study) Topic Objectives Topic 1: Introduction Welcome Where Are You? What Influence Do You Have? Topic 2: Overview of RCM Analysis Analyze the impact of Reliability Centered Maintenance (RCM) Analysis on Supportability and Supportability Analysis. Topic 3: Set Up – Building a Plan and Gathering Inputs Examine RCM Analysis planning considerations, analysis tools, and data inputs. Topic 4: Analysis – Determining Maintenance Tasks and Intervals Examine the RCM analytical process and its steps. Analyze failure maintenance strategy options resulting from RCM Analysis. Relate RCM to the Condition Based Maintenance Plus (CBM+) process. Examine diagnostic, prognostic, and health management capabilities in the CBM+ process and their impact on Supportability and Supportability Analysis. Topic 5: Report Findings – Data Management and Communication Paths Examine reporting requirements and communication paths for managing RCM Analysis results. Topic 6: Exercise and Simulation Find and validate applicable inputs from previous analyses Given a specific failure mode, determine the most applicable and effective failure maintenance strategies and intervals. Topic 7: Summary Coordinates Consistent White space
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