1. David Baglee Dr. David Baglee. School of Computing & Technology E: david.baglee@sunderland.ac.uk T: 0191 515 2869 Reliability Centred Maintenance

2. David Baglee RCM History 60’s: RCM developed in the airline industry 70’s: RCM used in the army and the American Navy 1978: first use of the term “Reliability Centered Maintenance” in Nowlan & Heap’s book: this book showed that a strong correlation between age and failure rate did not exist 80’s - 90’s: transfer of the RCM methodology to other industrial sectors (railways, chemical industry)

3. David Baglee The Nature of Failure Failure Rate Life

4. David Baglee RCM Start up Establishment of an RCM project group –one person from the maintenance function –one person form the operations function –an RCM specialist Definition of objectives and scope of the analysis Definition of boundary conditions with respect to safety and environmental protection

5. David Baglee The Seven Questions of RCM 1.What are the functions and performance standards? 2.In what way does it fail to fulfil its functions? 3.What causes each failure? 4.What happens when each failure occurs? 5.In what way does the failure matter? 6.What can be done to prevent each failure? 7.What should be done if a suitable task can not be found?

6. David Baglee 1. What are the functions? Primary –Main reason Secondary –Support, appearance, containment What does it do vs. What can it do?

7. David Baglee 2. In what way does it fail to fulfil its function? Record ALL failures associated with each function Identical items can have different failures

8. David Baglee 3. What causes each failure? What failure mode should be listed? Severe & Past Normal Human Error Design Failure modes which are already being prevented Failures which have not yet happened but do have a high probability of happening

9. David Baglee 4. What happens when each failure occurs? The effect of failure should be recorded –Does it pose a threat to Safety & Environment? –Is production affected? –Can it cause secondary damage?

10. David Baglee 5. In what way does each failure matter? Different failures have different measures of severity –Component, sub-component (hidden function) –Individual equipment –Line –Cell –Health & Safety

11. David Baglee 6. What can be done to prevent each failure Run-to-fail TPM CBM Preventive scheduled maintenance

12. David Baglee 7. What should be done if a suitable preventive task cannot be found? Redesign equipment Redesign production line Pareto analysis Decision tools

13. David Baglee Data collection The data necessary for the RCM analysis may be categorized and collected in the following three groups: Design data Operational data Reliability data The revised tasks and procedures must be documented in a way that ensures that they will be easily understood and performed by the people who do the work

14. David Baglee Implementation Define the scope and objectives of the project Establish review groups –facilitator –project manager –operations personnel functions and performance standards –maintenance personnel types of failures most appropriate condition monitoring techniques –maintenance and operations personnel consequences of identified failures

15. David Baglee Implementation (2) Plan senior management audits Senior management has to agree on –definition of functions and performance standards –identification of failure modes –description of failure effects –assessment of failure consequences –selection of tasks Implement the selected tasks Document the tasks and procedures

16. David Baglee Benefits Cost saving –shift from time-based to condition-based work workload reduction spare part usage reduction –improved operation performance Rationalization –unnecessary preventive work is eliminated Improved safety Improved environmental integrity

17. David Baglee Benefits (2) A precise and comprehensive maintenance database –during the analysis, information is gathered in a coherent form Education –improved overall level of skill and technical knowledge Improved teamwork Greater motivation of individuals

18. David Baglee Summary (1) Structured methodology to identify: – How, why & What Identifies the ‘root cause’ Helps to develop preventive maintenance schedules for equipment and sub equipment Requires a large amount of data Often ‘stronger’ if used with TPM/CBM

19. David Baglee Summary (2) In essence, two objectives exist: 1. Determine the maintenance requirements of the physical asset within its current operating context THEN 2. Ensure that these requirements are met as cheaply and effectively as possible RCM is objective one, TPM focuses on objective two

20. David Baglee Summary (3) TPM is made up of two particular tools –5 Why –PM analysis Both are “after the fact” RCM was developed to provide the best chance of designing appropriate countermeasures before they occurred

21. David Baglee Summary (4) Key is to focus maintenance resources on the areas where maintenance matters (RCM) Develop methodology to suit particular problem and equipment (TPM) or (CBM) Whatever “mix” of TPM is used a maintenance schedule should be developed using RCM. TPM and RCM should not compete but complement

22. David Baglee Examining the Processes of RCM and TPM: What do they ultimately achieve and are the two approaches compatible? by Ross Kennedy President, The Centre for TPM (Australasia)