1. " Copyright 2002, Information Spectrum, Inc. All Rights Reserved." RCM DECISION LOGIC Module 5 UNIT II RCM PROCESS

2. IntroductionIntroduction Module Preview: IntroductionIntroduction RCM Decision Logic RCM DECISION LOGIC Failure Consequences Task Evaluation Task Selection Review and Summary

3. Module Objectives: IntroductionIntroduction 1. Describe the RCM Decision Logic 2.Identify the four types of failure consequences that make up the branches of the RCM Decision Logic tree 3.Describe the RCM Task Evaluation Process RCM DECISION LOGIC

4. Module Objectives: IntroductionIntroduction 4. Identify the following task types: ServicingLubrication On Condition Hard Time Failure Finding 5. Introduce the RCM Task Selection Process end RCM DECISION LOGIC

5. 1. Identify Team and responsibilities 4. Identify and document Review Process 2. Identify analysis items 5. Orientation/Training 3. Prioritize Items 6. Ground Rules and Assumptions PLANNING AND PREPARATION ANALYSIS RCM Process Analysis Approac h/ RCM Plan Analysis MaintenanceRequirementsMaintenanceRequirements MaintenanceProgramMaintenanceProgram DataData 1.Equipment Kick-off Meeting 2.Initial Data Gathering 3.Hardware Partition 4.Function 5.Functional Failure 6.Failure Mode 7.Failure Effects 8.Failure Consequences 9.Task Evaluation 10.Task Selection 1.Package Maintenance Task 2.Implement Other Actions Results IMPLEMENT RESULTS 1.Emergent Issues 2.Age Exploration 3.Hardware Changes 4.Trend/degrader analysis 5.Document Reviews SUSTAIN RCM Decision Logic

6. RCM DECISION LOGIC Process used to determine what action should be taken to eliminate or lessen the consequences that result from the occurrence of a failure mode RCM Decision Logic Purpose:Purpose: RCM DECISION LOGIC

7. Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? YES Evident NO Hidden Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety? Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety? YES Evident Safety/ Environment YES Hidden Safety/ Environment NO Hidden Economic/ Operational Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, Other Action NO Evident Economic/ Operational Select BEST OPTION Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? YESEvident NOHidden Does failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation? Does hidden failure mode in combination with second failure/event cause function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation? YESEvidentSafety/Environment YESHiddenSafety/Environment NOHiddenEconomic/Operational Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, Other Action NOEvidentEconomic/Operational Select BEST OPTION

8. RCM DECISION LOGIC Consequences of Failure

9. FailureConsequences Failure Consequences Use of : Failure consequences: the impact that the effects of a failure have on safety, operations, and the environment … and whether the failure is evident to the operator When the failure consequences warrant attention, the goal of RCM is to control the consequences by: avoiding them (reducing their frequency) avoiding them (reducing their frequency) reducing their severity reducing their severity RCM DECISION LOGIC

10. Failure Consequences Failure consequences are categorized in two steps: Failure consequences are categorized in two steps: Hidden or Evident Hidden or Evident Safety/Environment or Operational/Economic Safety/Environment or Operational/Economic Identifying:Identifying: RCM DECISION LOGIC

11. Identifying:Identifying: Failure Consequences Failure Consequences Step 1: Evident Failure: A failure that, by itself, is apparent to the operator under normal circumstances Evident Failure: A failure that, by itself, is apparent to the operator under normal circumstances Hidden Failure: A failure that is not apparent to the operator under normal circumstances Hidden Failure: A failure that is not apparent to the operator under normal circumstances RCM DECISION LOGIC

12. Question 1: Is the functional failure or effect of the failure mode, on its own, EVIDENT to the OPERATOR while performing NORMAL DUTIES? Evident Hidden Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? YESNO EvidentSafety/Environment HiddenSafety/Environment EvidentEconomic/OperationalHiddenEconomic/Operational YESNONOYES Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary /event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Failure Consequences RCM DECISION LOGIC EVIDENT - Apparent to operator without special monitoring. OPERATOR – Crew/Equipment Operator

13. #2 #1 Failure Consequences The evident and hidden groups are further divided based on failure effects: Safety Safety Environment Environment Operations Operations Economics Economics 2 Fly-ins Failure Consequences Step 2: Identifying:Identifying: RCM DECISION LOGIC

14. Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? Evident Hidden Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? YESNO EvidentSafety/Environment HiddenSafety/Environment EvidentEconomic/OperationalHiddenEconomic/Operational YESNONOYES Does the occurrence of the hidden failure mode/event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Failure Consequences Question 2: RCM DECISION LOGIC

15. Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? Evident Hidden Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? YESNO EvidentSafety/Environment HiddenSafety/Environment EvidentEconomic/OperationalHiddenEconomic/Operational YESNONOYES Does the occurrence of the hidden failure mode in combination with a second failure/event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Failure Consequences Question 3: RCM DECISION LOGIC

16. Failure Consequences In summary, failures are categorized by consequences. RCM uses four categories: Evident Safety/Environmental Evident Safety/Environmental Hidden Safety/Environmental Hidden Safety/Environmental Evident Economical/Operational Evident Economical/Operational Hidden Economical/Operational Hidden Economical/Operational Categories:Categories: RCM DECISION LOGIC

17. Failure Consequences Evident failure: Eliminate/reduce the consequence of single failure Eliminate/reduce the consequence of single failure Hidden failure: Eliminate/reduce consequences of multiple failure Eliminate/reduce consequences of multiple failure Eliminate/reduce economic consequence of single failure Eliminate/reduce economic consequence of single failure A Multiple Failure is a c ombination of a hidden failure plus a second failure or other event that makes the hidden failure evident Managing:Managing: RCM DECISION LOGIC

18. Failure Consequences Safety/Environmental failure: Must prevent the consequences of failure Must prevent the consequences of failure Economic/Operational failure: Prevent or allow failure Prevent or allow failure Summary: RCM decision logic process provides the appropriate management strategies for each consequence category Managing:Managing: RCM DECISION LOGIC

19. EVIDENT HIDDEN Safety/EnvironmentEconomic/OperationalEconomic/OperationalSafety/Environment Consequences Branches: Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Select BEST OPTION Failure Consequences RCM DECISION LOGIC

20. Task Evaluation RCM DECISION LOGIC

21. Purpose:Purpose: To determine what actions can be taken to prevent a failure mode from occurring; or, if not prevented, to lessen its effects to an acceptable level. Task Evaluation RCM DECISION LOGIC

22. EVIDENT HIDDEN Safety/ Environment Economic/ Operational Economic/ Operational Safety/ Environment Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Select BEST OPTION Preventive Maintenance Tasks: Task Evaluation RCM DECISION LOGIC

23. Servicing:Servicing: The replenishment of consumable materials that are depleted during normal operations. The replenishment of consumable materials that are depleted during normal operations. Task Evaluation RCM DECISION LOGIC

24. Lubrication:Lubrication: The scheduled lubrication of a component (usually based on the manufacture’s recommendations) where the item’s design requires a non-permanent lubricant for proper operation Task Evaluation RCM DECISION LOGIC

25. On-Condition Task Evaluation Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure. RCM DECISION LOGIC

26. Hard Time Task: Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure. Task Evaluation RCM DECISION LOGIC

27. Failure Finding: A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred. Task Evaluation RCM DECISION LOGIC

28. 5 Fly-ins Preventive Maintenance Tasks: Task Evaluation S (Servicing Task) - Replenishment of consumable materials depleted during normal operations S (Servicing Task) - Replenishment of consumable materials depleted during normal operations L (Lubrication Task) - Replacement of a lubricant based on manufacturer’s predicted or measured life of the lubricant L (Lubrication Task) - Replacement of a lubricant based on manufacturer’s predicted or measured life of the lubricant OC (On Condition Task) - Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure OC (On Condition Task) - Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure HT (Hard Time Task) - Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure HT (Hard Time Task) - Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure FF (Failure Finding Task) - FF (Failure Finding Task) - A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred. RCM DECISION LOGIC

29. Other Action Warranted: Other Action: Usually a one time action, other than PM, that will effectively reduce the consequences of failure to an acceptable level Item redesign Item redesign Change in an operational or maintenance procedure Change in an operational or maintenance procedure Operating restrictions Operating restrictions Etc. Etc. Task Evaluation RCM DECISION LOGIC

30. Other Action Warranted: Consider when No acceptable PM task can be found for safety/environmental consequence failures No acceptable PM task can be found for safety/environmental consequence failures Other Action is preferable to PM and run to failure Other Action is preferable to PM and run to failure Other action, in combination with PM, will beneficially reduce consequences or frequency of failure Other action, in combination with PM, will beneficially reduce consequences or frequency of failure Task Evaluation RCM DECISION LOGIC

31. RCM Decision Logic Results: Once a failure mode is subjected to the RCM Decision Logic, at least one of the following outcomes will result: PM Required PM Required No PM Required No PM Required Other Action Warranted Other Action Warranted Task Evaluation RCM DECISION LOGIC

32. Task Selection RCM DECISION LOGIC

33. Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? YES Evident NO Hidden Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety? Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety? YES Evident Safety/ Environment YES Hidden Safety/ Environment NO Hidden Economic/ Operational Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, Other Action NO Evident Economic/ Operational Select BEST OPTION Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? YES Evident NO Hidden Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? YES Evident Safety/ Environment YES Hidden Safety/ Environment NO Hidden Economic/ Operational Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, Other Action NO Evident Economic/ Operational Select BEST OPTION

34. Selection Process: One or more PM tasks may prevent or reduce the probability of failure to an acceptable level. These tasks along with... a decision to allow the failure mode to occur (no PM) a decision to allow the failure mode to occur (no PM) some “other action”... some “other action”... … form a pool of options from which solutions can be generated. Task Selection RCM DECISION LOGIC

35. Review and Summary Introduction Introduction Learning Objectives RCM Decision Logic RCM Decision Logic Task Evaluation Task Evaluation Task Selection Task Selection 7 Fly-ins RCM DECISION LOGIC Module Objective Module Objective

36. End of Module up next…….. UNIT III RCM Software Review End of Module up next…….. UNIT III RCM Software Review