RCM - Maintenance

Philosophy of the Future?

by Peter Ormond, Strategic
Corp., Australia

Reliability Centred
Maintenance

Original paper by Nowlan and Heap,

1978
Major re-work in RCM II by John
Moubray
SAE Standard JA1011 in 1999

Maintenance Philosophies
Breakdown
Maintenance

Industrial
Revolution

Preventive or
Change-out
Maintenance

Second
World
War

Predictive or
Condition
Based
Maintenance

Reliability
Centred
Maintenance

Mid 60s

Mid 80s

BHPs Experience

Steel Industry World Wide Review

Man-hours per Liquid Tonne of Steel

Four Best Practice Organisations
Biggest difference Maintenance
treated as a PROFIT CENTRE

BHP was managing Maintenance as

COST CENTRE

BHP Action Plan

Understand Problem
Set Overall Target

Target 40% Reduce in Maint. Cost Per

Tonne in 5 years

Develop Approach for Solution

7 Step Plan

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Education

Develop a new technique for applying

training - SBL
Develop a high level training package

Introduction to Maintenance and its

Management

Apply training package to ALL

employees

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Roles & Responsibilities

New understandings required new

definitions
Some changes to organisational
structure
Once-off exercise

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Measurements

The only way to make permanent change

is to change the way things are measured
Split measurements between KPIs and
the PIs that feed them
KPIs are ALL Historical, Summary and
UNCONTROLLABLE
Measuring is not enough, interpreting the
measures is the important step

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Processes and Systems

Follow-on from all the previous steps

Includes fully developed processes,
procedures, documentation, etc.
Also includes adequate computer
systems, both hard and software, as
well as appropriate training

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Strategy Based
Maintenance

Understand Profit Centre Maintenance

Travel World looking for solutions

RCM recognised as fitting exactly with

required philosophy
Love results Hate effort required

Develop Methodology to enhance

RCM (RCM Turbo)

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Continuous Maintenance
Improvement

Appoint responsibility
Formalise process
Recognise shortcomings of P-D-C-A
Change Act to AUTHORISE

BHPs 7 Step Plan

1.
2.
3.
4.
5.
6.
7.

Re-Education
Re-Define Roles & Responsibilities
Re-Develop Measurements
Provide Processes and Systems
Apply Strategy Based Maintenance
Formalise Continuous Improvement
Focus on Waste Reduction

Waste Reduction

Very similar to Continuous

Maintenance Improvement
Look outside normal Maintenance
sphere
Same structure but less frequent

BHP Steels Results

Achieved 50% reduction in 6 years

Pointed to two factors having greater
impact than anticipated:

Re-Education of all employees into

common understanding of Maintenance
Implementation of RCM (RCM Turbo)

World Wide View

Late 80s

Paper based analyses

Several successful exercises
No PC Tools
Almost no-one had heard of RCM

World Wide View

Mid90s

Many heard of RCM but few

knowledgeable
Several Tools
Other systems claiming to be RCM
SAE Standard JA1011

World Wide View

Current 2000+

Few organisation not heard of RCM

Most organisations have some-one with
detailed knowledge
Many organisations have Reliability Group
Many others trying to start projects
RCM Incorporated into University Courses

How does it all fit

together?

Business Plan
Plant Strategy

Operating requirements
Inventory plant items
Life Plans for critical plant items
(RCM analysis)

CMMS
Task lists
Maintenance plans
Work orders

Document Retrieval System

Work instructions

Improvement Steps

RCM-Turbo The Versatile Tool

Revie
w
KPI
Scheduli
ng
Resource
Bal

Opt
Freq

Grp
Tasks

Task
Analysis

Fail
Analysis
Equip
Codes
Reactive
Maintenance
Proactive

Systems Maturity

Improvement Steps

RCM-Turbo The Versatile Tool

Revie
w
KPI
Scheduli
ng
Resource
Bal

Opt
Freq

Task
Analysis

Grp
Tasks

Fail
Analysis
Equip
Codes
Reactive
Maintenance
Proactive

CMMS

Systems Maturity

Improvement Steps

RCM-Turbo The Versatile Tool

Revie
w
KPI

RCM

Scheduli
ng
Resource
Bal

Opt
Freq

Task
Analysis

Grp
Tasks

Fail
Analysis
Equip
Codes
Reactive
Maintenance
Proactive

CMMS

Systems Maturity

Improvement Steps

RCM-Turbo The Versatile Tool

RCM-Turbo

RCMTurb
o

Revie
w
KPI

RCM

Scheduli
ng
Resource
Bal

Opt
Freq

Task
Analysis

Grp
Tasks

Fail
Analysis
Equip
Codes
Reactive
Maintenance
Proactive

CMMS

Systems Maturity

Frequency Optimisation
MTBF

Total
Annual
Business
Cost of
Maint.

Cost of Failure

Cost of Inspection
Time
Optimum
Frequency

FTM - Optimum Frequency based on Probability of Failure in MTBF

Warning Time
P
F1

70% Confidence non-failure

92% Confidence non-failure
Warning Time

Frequency Optimisation
MTBF

Total
Annual
Business
Cost of
Maint.

Cost of Failure
Cost of Planned Repair
Cost of Inspection
Time
Optimum
Frequency

Warning Time

CBM - Optimum Frequency based on Confidence of non Failure in Warning Time

Frequency Optimisation
Graph

Benefits Obtained from

Frequency Optimisation

Many Tasks Increase in Frequency

Increasing Reliability
Many Tasks Reduce in Frequency
Reduced Costs without Compromising
Reliability
Average Cost Reduction 10% 15%
Assists What If..? Scenario Testing
Justification of Maintenance Decisions

Benefits of RCM

Changing Organisations to Profit

Centre rather than Cost Centre
Maintenance
A Methodology to apply Business
Decision to Maintenance Planning
Supports all Current Maintenance
Techniques
Consistent with and sub-part of TPM

Title Question

RCM Maintenance Philosophy of the

Future?

YES !