1. Reliability Centered Maintenance

2. Condition Monitoring Reliability Vibration Analysis Oil Analysis Performance Analysis Failure Analysis

3. Root Cause Failure Analysis Analysis of Failure Confirmation of Analysis Real Reason for failure Prevention of Failure Approach to RCFA Why Why analysis Ishikawa Diagram

4. RCFA Why- Why Steps Bearing Failed Why? Spall in Inner Race Why? Caused by Over Load Why? Belt Load More Why? And So on till you cannot further breakdown.

5. RCFA Ishikawa Diagrams Bearing Failed Overload LubricationForeign Matter Belt Unbalance Over Tightening Skewed Pulley Lack of Training

6. Reliability Centered Maint.

7. RCM – 7 Questions What are the functions and associated performance standards in present operating context? In what ways does it fail to fulfill its functions? What causes each functional failure? (Modes) What happens when each failure occurs? (Effects) In what way does each failure matter? (Consequences) What can be done to predict or prevent each failure? What should be done if a suitable proactive task cannot be found?

8. Step 1 – Define Failure What are the possible failures List all failures Example Pump Does not give Flow Pump does not give Pressure Pump Has High Vibration Pump Has High Noise

9. Step2 – Identify Modes Six distinct modes of Failure Traditional – Increasing probability of failures with age Modified – Decreasing, Steady and Increasing probability – Bath Tub Curve Modern – Additional 4 modes

10. Modes of Failure % Prob Time 1 2 3 4 5 6

11. Failure Modes Time 1 2 3 4 5 6

12. Step 3 – Identify Effects Effects of Each Failure Mode in the Particular Failure Type Example High Vibration Mode  Type 6 Effect  Unreliable operation Cracking of supports Brinneling of bearings etc…

13. Step 4 –Identify Consequences Identify Consequences for each effect Example Support Cracks Consequences  Leakage & Fire Environmental Degradation

14. Step 5 – How to Predict / Prevent Identify Prediction and Prevention for each Failure Driver is Consequence More Severe Consequence  Prevention & Prediction Failure Prevention Proactive Task Default Actions

15. Step 6 – Task Application Proactive Tasks Restoration Task – PM Concept On Condition Task – PdM/ CBM Concept Default Actions Failure Finding Redesign Run-to-failure

16. Step 6 – Task Selection Cost to Benefit Analysis Consequence Evaluation Environment Consequece  Predict & Re- Design Operation Consequence  Prevent And So on…

17. In Conclusion RCM Primarily a Risk recognition & Mitigation technique Involves detailed documentation Effective in Combination With FMEA or RCFA With TPM & TQM

18. End of Part -5