Maximizing equipment availability and reliability while reducing cost investment starts with a clear detailed maintenance strategy -- a "living reliability centered maintenance (RCM) Program. The outcome of the program is a collection of defined condition-based maintenance job plans and regular inspections. We need to work efficiently and effectively. We must not only do the work right, we must do the right work. Maintenance needs to be based upon the operating consequences of failure. An RCM program identifies your critical equipment and required maintenance tasks.
Reliability Centered Maintenance typically has three stages:
- Living RCM
This first blog will summarize these stages. Other details will be covered in future blogs.
Reliability Centered Maintenance stages
Stage 1: Analysis
- Identify functional systems
- Identify functional system boundaries and assign system criticality
- Identify equipment functions and functional failures
- Analysis of functional failures modes and effects
- Critical analysis logic - Identify critical and non-critical failures
- Identify Required maintenance tasks
- No mintenance: Run to failure
- On-condition maintenance: Scheduled routes of inspections and tests
- Scheduled rework maintenance: repairs and overhauls
- Scheduled discard maintenance: Replace
- Scheduled failure-finding maintenance: Fault-finding tasks
- Redesign: Redesign if risk cannot be brought to an acceptable level
Stage 2: Implementation
- Implementation requires an asset and work management system
- Identify critical and non-critical equipment
- Identify maintenance tasks and job plans
- Record maintenance actions and as-found conditions
- Capture asset conditions for monitoring in condition monitoring application
- Install RCMd-driven PM program (maintenance optimization). Clearly defined quantitative PM and PdM program
- Install equipment monitoring on defined conditions and Implement Condition Monitoring Program, PdM
- Train workforce
Stage 3: Living RCM
- Define "Living RCM standards"
- Update RCM decision logic data as conditions change
- Establish peer review action team
- Modify RCM program based upon changing conditions
- Record results of maintenance tasks as the basis for adjusting initial conservative intervals or conditions
- Analysis of operating data to determine extension or elimination of maintenance tasks
- Begin continuous audit and re-evaluation of systems and technology and equipment improves
RCM has been referred to as an organized common sense approach into a structured maintenance program.
The Maintenance objective is to provide required
availability and reliability while optimizing maintenance expenditures.
More thoughts and details to be provided in future blogs. - Be Safe!