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Reliability Centered
Maintenance;
Are we Ready

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PRESENTATION OUTLINE

What is RCM
RCM Methodologies
Applications & Requirements
Conclusions

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Reliability Centered Maintenance

Maintenance Trends

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Reliability Centered Maintenance

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Reliability Centered Maintenance

Preventive Maintenance
Whole sale implementation of PM
recommendations, without considering
equipment criticality or condition, may
result in work load that is too large to
achieve.
consciously chosen, effectively
implemented and properly
documented maintenance programme
seem to be an answer

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Reliability Centered Maintenance

Reliability
"The probability that a system will
perform satisfactorily for given
period of time under stated
conditions."
stated as a text book definition by
Dimitri Kececioglu

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Reliability Centered Maintenance

RCM
"the level of reliability achieved with an
effective maintenance program. This
level is established by the design of each
item and the manufacturing processes
that produced it. "
Nowlan and Heap

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Reliability Centered Maintenance

RCM involves
Establishment of Safe Minimum levels
of Maintenance
Changes to Operating Procedures &
Strategies
Establishment of Capital Maintenance
Regimes & Plans

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Reliability Centered Maintenance

RCM METHODOLOGIES

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Reliability Centered Maintenance

7 steps of
RCM

What are
the
functions
of the
asset?

In what
way can
the asset
fail to
fulfill its
functions?

What
causes
each
functional
failure?

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Reliability Centered Maintenance

7 steps of RCM
(cont.)

What
happens
when each
failure
occurs?

What are
the
consequenc
es of each
failure?

What should
be done to
prevent or
predict the
failure?

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Reliability Centered Maintenance

Step 7

What should
be done if a
suitable
proactive
task cannot
be found?

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Outcome of 7 RCM
questions

What would be
done to predict
What to be
or prevent
done if suitable
failure (Default
proactive task
Actions)
cannot be
found

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Failure Management
Strategies based on
Established common
failure patterns
Failure Mode Effects
Analysis (FMEA)

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Failure Management
Strategies include
Schedule Inspections
i. Failure Finding
ii. On - Condition

Scheduled Preventive
Maintenance
Run to Failure
Design Changes

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Reliability Centered Maintenance

RCM APPLICATIONS

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Reliability Centered Maintenance

RCM gaining grounds in the wake of

Diminishing maintenance funds

Pressure for machines to stay on
line due to high electricity
demands
Scarcity of skilled maintenance
staff

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Reliability Centered Maintenance

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Reliability Centered Maintenance

Applications of RCM

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CONCLUSIONS

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Focuses on
Appropriate amount of
maintenance
Right time
Prevent forced outages
Eliminate unnecessary
maintenance

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To achieve
Increase in Cost Effectiveness
Machine Uptime
Greater Understanding of Level of Risk
that organization is managing

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Reliability Centered Maintenance

Features of RCM
May be labor intensive and time consuming to set
up initially
May require additional monitoring of quantities, like
temperature and vibration etc to be effective. This
would mean new monitoring equipment with its own
PM or human monitoring with multiple inspections
May result in a run to failure or deferred
maintenance philosophy for some equipment.

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Reliability Centered Maintenance

Requirements
Monitoring equipment parameters such as
temperatures, pressures, vibrations,
leakage current, dissolved gas analysis etc
Testing on periodic basis and/ or when
problems are suspected such as Doble
testing, vibration testing and infrared
scanning

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Reliability Centered Maintenance

Requirements of RCM (cont.)

Monitoring carefully the operatorgathered data
Using intelligent Assets Management
Systems which would reduce overall
cost by focusing only on equipment
that really needs attention

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Reliability Centered Maintenance

CONCLUSIONS
Most practical approach for RCM is
always a combination of CBM and PM,
Monitoring, testing and using historical
data as well as PM schedules to guide
when equipment should be maintained

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Thank You for Your Audience!

Any Contributions?