1. Reliability Centered Maintenance Analysis
Lesson 8
Reliability Centered Maintenance Analysis

2. 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.

3. 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

4. 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.

5. 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

6. Topic 2: Overview of RCM Analysis

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. Topic 3: Set Up – Building a Plan and Gathering Inputs

14. 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.

15. 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

16. 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

17. Topic 4: Analysis – Determining Maintenance Tasks and Intervals45

18. 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

19. 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

20. 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

21. 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.

22. 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!

23. 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.

24. 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.

25. 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

26. 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

27. 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

28. 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

29. 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

30. 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

31. 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

32. 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

33. 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

34. 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

35. 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

36. 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

37. Topic 5: Report Findings – Data Management and Communication Paths

38. 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

39. 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

40. 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.

41. Map Failure Modes to Tasks
The failure modes identified in the RCM Analysis eventually translate into preventive tasks in the Logistics Product Database.

42. Inspect UAV SATCOM Control Task
CAUTION
INSPECT
INSPECT

43. RCM Analysis Results IPT Communication Paths

44. Topic 6: Exercise and Simulation

45. 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

46. 10 minutes Group grade Identify data inputs to conduct RCM Analysis
In Blackboard, select the Lesson 8: Exercise link in the lesson folder.

47. 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.

48. Topic 7: Summary

49. 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

50. 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