ORGANIZADO POR:

Ing. James Reyes-Picknell

e Ing. Jesús R. Sifonte
Conscious Asset y PdMTech / CMMI

RCM-R®: Re-Engineered
- Mejoras
a una técnica exitosa
ORGANIZADO POR:
 Presentation Contents

1. RCM-R® Background
2. Asset Data Integrity
3. RCM per SAE JA1011
4. Failure Data Analysis
5. Continuous Improvement
6. Summary
RCM-R® Background

ORGANIZADO POR:
 RCM – a brief history
• 1960’s: too many airline crashes
– MSG-2 not working as intended
• 1970’s study by Nowlan & Heap  RCM
– Changes to MSG-2 (now MSG-3)
• 1980’s Military and Nuclear adapt RCM
• 1990’s Commercialization
– Lots of competition, some less rigorous methods
– Led to creation of standards: SAE JA-1011
• 2000’s Refinement
– SAE JA-1012
• Continued competition among various methods
– Some successes, many failures
• Little of significance has happened since then
• Until now …
 RCM produces good FMEA but….

• Poor consequence management policies and maintenance tasks

selection.
– Lack of maintenance knowledge (CM)
– Too many T versus C tasks
– No “One-time change” tasks assigned
• Still experiencing critical failures

Fortunately….

• Good WO data can save us…

• But good data is difficult to find
 RCM is often misapplied….
• Attempt to do it without being “ready”  results sit on the shelf
• No team approach (only maintenance)
• Poor definition of failure causation
• Shortcuts focus only on critical assets with poor understanding of
what is / is not critical!
• Desire to get results quickly and cheaply
– Use of contractors  no ownership of results
– Use of students  who is teaching who?
– Shortcut and database extraction methods  completely out of touch with
the site needs often leading to poor decisions
Your organization depends on Physical Assets for
attaining Financial, Safety and Environmental related
goals. Such goals are put at risk if assets are not
reliable! Optimum Maintenance is NOT OPTIONAL today.
 The Pillars of RCM-R®

• Asset Data Integrity

• RCM per SAE JA1011

• RAM / Failure Analysis

• Continuous Improvement
Asset Data Integrity

ORGANIZADO POR:
 Value is obtained from GOOD data…. It is needed for Optimum Results

Top notch WO data Reliability Data CM Data

– Operating time – MTBF, MTTR, A – Process
– Failure cause – Failure Pattern – PdM
– Craft man-hours – Downtime – NDT
– Spare parts – Productivity – RBI
RCM – SAE JA1011

ORGANIZADO POR:
 SAE JA1011
Evaluation Criteria for Reliability-Centered Maintenance (RCM)
Processes

• Describes the minimum criteria that any process must possess to

be deemed a compliant RCM process.

• Is intended to provide a means for evaluating whether a given

process remains true to the tenets of RCM as it was originally
conceived.

• It is especially useful to people who wish to purchase RCM

services (training, analysis, facilitation, consulting, or any
combination thereof).
 RCM is …

• a systematic process to determine what must be done to keep assets doing

what operators need them to do in their current operational context.

• In other words, it is a process of producing effective “failure consequence

management policies”.

• It produces maintenance plans for which maintenance tasks are prioritized

according to their consequences and targeted specifically at failure causes.

• It also produces other decisions on operator performed tasks, one time

changes to procedures or processes, design changes and even, in the right
circumstances, running an asset to failure.
 The 7 Questions of RCM in practice…
FM & Causes Classification – ISO
14224

1. What are the functions and associated desired standards of

2. performance
3. In what
What waysof
causes
theit asset
can
each fail toin
functional
its present
fulfil operating
its functions
failure
context
(functional
(failure modes)? failures)?
(functions)?

RCM-R® Functions and Functional Failures With Classification (Critical, Non-Critical and Hidden) Failure Modes/Type and Root Causes/Type

Function
#
Function, Performance level and operating context # Functional Failures (Loss of Function)
Functional
Failures Failure Modes Q3 Root Causes
Classification

Type

Type
# #

Due to a wrong selection of the

a DES
coupling.

1 Pump Coupling Wear MAT b Due to normal use. AGE

Q1 Q2 c
Misalignment caused by wrong
practices
MGT
2 To supply a minimum of 30 gpm of caustic water A Unable to supply caustic water at all. C
Low suction pressure due to a
a AGE
dirty strainner.
Low suction pressure due to a
2 Pump Cavitation MEC b DES
wrong pipe design

c Due to wrong operation. O&M

 The 7 Questions of RCM in practice…

Risk Assessment – ISO 31000

4. What happens when each failure occurs (failure effects)?

Q4
 The 7 Questions of RCM in practice…

5.
7. In what
6. What
What way does
should
should be each
bedone
done iftoafailure matter
suitable
predict (failure
orproactive
prevent consequences)?
task
each cannot be
failure
found (default
(proactive actions)?
tasks and task intervals)?

Q5 Q7

Q6
Failure data analysis

ORGANIZADO POR:
Why failure data analysis?

R(t)
F(t)
h(t)
T*

• Reveals true physics of failure…

• Useful to refine failure Consequence Management Policy
• Tool for optimizing costs
• Calculation of optimum PM frequency
 Failure Data Analysis Example

Case Study Background

• Mining Industry
• Asset: Loader
• Failure Cause: Pin wear due to age

• Operating Contexts:
– Loader B = Moderate Loads and Speed
– Loader A = Heavier Loads & Higher
Speed

• Manufacturer Replacement time: 28,000

hours
 Failure Data Analysis Results

Loader A Loader B
Ages = 13,260, 15963, 21396 Ages = 26100, 30718, 36041

• β = 4.98 (Strong wear out) • β = 3.81 (Strong wear out)

• η = 18,659 hours • η = 36,642 hours

• Maint. Strategy = T • Maint. Strategy = T

• Optimum Replacement = 10580 hours • Optimum Replacement = 17037 hours

• Cf / Cp ratio = 5 • Cf / Cp ratio = 5
Continuous Improvement

ORGANIZADO POR:
What happens when things change?
Analysis is completed, but changes continue to occur

1. Function changes.
2. New failures or changed failure rates.
3. Asset Modifications.
4. New Maintenance Technologies.
5. Others…

RCM analysis needs to be keep “fresh” with a continual

improvement processes or it actually goes “stale” and it no longer
delivers results as it once did
 RCM-R® vs “Classic” RCM
Classic RCM-R®
• Primary function may contain several standards • Requirements for method applicability (Pre-Work)
clearly established.
• No classification of functional failures
• Each function is treated separately
• Failure modes may or may not identify causes
• Functional failures classified by criticality (filtering
• No classification of failure modes
opportunity) and detectability (evident vs hidden)
• No formal assessment of risks from effects
• Failure modes and their causes identified
• Uses one decision diagram
• Failure modes and causes classified by type (ISO 14224)
• Decision diagram does not deal with hidden
• Effects risk assessment per ISO 31000 (links to
operational and non-operational consequences
corporate risk management)
• Limited use of failure data, reliability analysis not
• Can choose decision diagram to suit whether or not
included in RCM process
operators will carry out tasks
• Training and text books only mention need to
• All consequences dealt with per SAE JA 1012
keep RCM “alive” after analysis completed
• Decisions classified for sorting
• Rigid training protocols prescribed
• Significant emphasis on data, data quality, reliability
• Extensive training period for facilitators with no
analysis to improve quality of decisions
enforcement of mentoring requirement
• Emphasis on continual improvement after analysis is
complete
• Various training options (classroom, online distance,
blend of online content and class)
• Only route to facilitation is via mentoring
Gracias por
su atención!
jsifonte@pdmtechusa.com
787-807-0670
www.pdmtechusa.com

james@consciousasset.com
705-252-8115
www.consciousasset.com
¡GRACIAS!

ORGANIZADO POR:
 Ing. James Reyes-Picknell
e Ing. Jesús R. Sifonte
Conscious Asset y PdMTech / CMMI

SI TIENES PREGUNTAS
O COMENTARIOS…
¡No dudes en acercarte!
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