LIFE CYCLE COSTING | HIGHLY ACCELERATED STRESS TEST PLANNING | STRESS ANALYSIS | DESIGN OF EXPERIMENTS
RELIABILITY-CENTERED MAINTENANCE (RCM)
Is Your Plant Running Safely/Eciently?
Is Your Fleet Fleet Enough?
Are Your Maintenance Costs Too High?
RCM Plan
RCM Process
Outcomes
Time or Cycle-Based actions?
Condition-Based actions?
Maintenance
Performance Optimization
Who? What? When?
Where? Why? How?
Run-to-Failure?
Proactive
Spare Parts and
Materials
What should the inventory
level be?
Where is the best place
to hold inventory?
Do standards need to
be developed?
What is the best feedback loop to
improve the design?
When should root failure
cause analysis be
performed?
THERMAL ANALYSIS | KNOWLEDGE MANAGEMENT | VENDOR QUALIFICATION
FAULT TREE ANALYSIS | RELIABILITY PREDICTION | FAILURE MODE EFFECTS AND CRITICALITY ANALYSIS | ALLOCATION
ROOT CAUSE FAILURE ANALYSIS | RELIABILITY PROGRAM SUPPORT
What is Reliability-Centered Maintenance (RCM)?
An analytical method based on Design for Reliability (DFR) and Design for Maintainability (DFM) Best Practices
to match your organizations preventive maintenance capabilities to the design characteristics of your product or
system.
Product/System
Requirements
Design for Reliability (DFR)
Design for Maintainability (DFM)
Failure Mode Information:
PoF
Analysis
HALT/HAST
Surrogate
Data
RCM Decision Analysis
Mode
RCM
Plan/Strategy
Accessibility
Testability
Times-toRepair
Human Factors
FMECA
(Evident & Hidden Failures)
RCM Task
C
Analysis
Field Performance
RCM Task
RCM Task
Failure Rate/Life Data:
Field Data
Analysis
Test Data
Analysis
Surrogate
Data
Weibull &
Trend Analysis
Induced
Failures
Maintenance Work
Orders per Year
Number of Maintenance
Personnel
Total Maintenance Hours
Optimized
Total Ownership Cost
PoF = Physics-of-failure
HALT = Highly Accelerated Life Test
HAST = Highly Accelerated Stress Test
FMECA = Failure Modes, Effects and Criticality Analysis
What Benefits does RCM Provide?
Identifies maintenance actions that will reduce the probability of catastrophic product/system failure
Identifies cost-effective maintenance actions
Promotes an optimal mix of maintenance action types
Applicable to DoD, government, industry and commercial systems, products and processes
RCM Strategies
Run to Failure
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Small items
Non-critical
Inconsequential
Unlikely to fail
Redundant
Preventive
Subject to wearout
Consumable
replacement
Failure pattern
known
Predictive
Random failure patterns
Not subject to wear
Preventive Maintenanceinduced failures
Proactive
Root-cause failure
analysis
Age exploration
Failure modes and
eects analysis
(FMEA)/Failure
modes, eects and
criticality analysis
(FMECA)
What Criteria is Used to Make RCM Decisions?
Failure consequences determine priority (safety- or function-critical)
Selection of each preventive maintenance task is based on inherent failure patterns
Scheduled maintenance is based on functional or safety consequences
Product/system redesign for safety may be required
Maintenance actions should be economically justifiable
Function
1
Is occurrence of a
failure evident to operating
crew in performance of
normal duties?
Evident Failures
Yes
Does the failure
cause a loss of function or
secondary damage that has
a direct and adverse effect
on operating safety?
Yes
Critical
Safety
Class A
Hidden Failures
No
Does failure
have a direct and
adverse effect on
operational
capability?
No
Class D
Yes
No
Scheduled
Scheduled maintenance
maintenance is
Operating
is required and must be
desired if it is
Scheduled
capability
Other
able to reduce risk to an
(economics)
effective in
maintenance is
regular
acceptable level or item
functions
reducing
Class B
desired if it is
must be redesigned
(economics) cost effective in
probability or
unless basic design
Class C
operational
reducing
constraints require
consequences to
corrective
acceptance of the
an acceptable
4
maintenance
6
identi ed risk
5
level
Is there
Is there an
an effective and
Is there an
effective and applicable
applicable preventive
effective and applicable
preventive maintenance
maintenance task or
preventive maintenance
task or combination of
combination of tasks
task or combination of
tasks that will prevent
that will prevent
tasks that will prevent
functional failures?
functional
functional failures?
Safety
Mission
All
Others
failures?
Yes
No
Submit a
safety related
design change
Describe and
classify task(s)
Scheduled
maintenance is
required to
reduce risk of
multiple failures
or unavailability
of function to an
acceptable
level?
Hidden or
infrequent
functions
Yes
No
Describe and
classify task(s)
Yes
No task
required
Describe and
classify task(s)
Is there an
effective and applicable
prevention task or combination
of tasks that will prevent
functional failures?
Yes
No
8
Describe and
classify work
Yes
No
Is a scheduled
failure nding
task available
and justi ed?
Describe and
classify task(s)
No task
required
Submit a safety
related design
change if appropriate
No
No task required
Submit a safety
related design
change if appropriate
Besides Safety Issues, What Other RCM Criteria Would
Drive a Potential Redesign Decision?
Decision criteria include:
How critical is the impact of failure?
Is the failed item expendable or not?
How effective is redesign at solving the problem?
Can Condition Monitoring help, and is it justifiable?
What about design redundancy?
Will a failure have a direct and adverse eect
on critical system or process functionality?
NO
Is the item expendable?
YES
YES
Can redesign solve the problem
permanently and cost-eectively?
NO
NO
Is there a Condition Monitoring (CM) technology (e.g., vibration testing/sensing,
thermography) that will give sucient warning (alert/alarm) of impending failure?
NO
Is design redundancy justied
by cost and priority ?
NO
Accept risk of failure
RUN TO FAILURE
Redesign
PROACTIVE MAINTENANCE
YES
Is there an eective PM task that
will minimize functional failure?
NO
YES
NO
Is CM cost and priority justied?
YES
YES
YES
Install redundant units
PROACTIVE MAINTENANCE
Dene PM Task and Schedule
PREVENTIVE MAINTENANCE
Dene CM Task and Schedule
PREDICTIVE MAINTENANCE
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Define product/system R&M requirements
Perform Design for Reliability RCM-related tasks
PoF Analysis
Define HALT/HAST and interpret results
Collect/analyze failure mode distributions
Collect/analyze surrogste data
Perform FMEA/FMECA and root cause analysis
Analyze and Assess Maintainability Design Attributes
Define and implement an RCM Decision Analysis Plan/Strategy
Significant function selection
RCM task evaluation selection & implementation
Collect, analyze and assess RCM performance data
Field and test failures, down to root cause
Weibull & trend analysis
Field maintenance data
Optimize RCM performance (feedback loop)
RCM-Related Documents
Maintenance Steering
Group (MSG-3)
NAVAIR 0D-25-403. Guidelines for
the Naval Aviation RCM Process
Army Pamphlet 750-40, Guide
to RCM for Fielded Equiptment
MIL-STD-3034, RCM Process
Society of Automotive
Engineers (SAE)
811 Court St. Utica, NY 13502
[email protected]1.877.808.0097
What Can Quanterion do to Help?
SAE JA 1011, Evaluation
Criteria for RCM
Processes
SAE JA 1012, A Guide to
the RCM Standard
Services
DESIGN PHASE
CONCEPT PHASE
Reliability/Functional
Block Diagrams
Reliability Prediction
Reliability Growth Modeling
FMEA/FMECA
Fault Tree Analysis
Risk and Safety Analysis
Component and
Materials Selection
Stress Analysis and Derating
Vendor Selection
Life Cycle Costing
Warranty and Sparing
Analyses
Design of Experiments
Reliability Centered
Maintenance
Requirements Analysis
Metrics and Goal Setting
System Modeling
Analysis of Alternatives
Allocation
Benchmarking
Reliability Gap Analysis
Reliability Program
Planning
PRODUCT DEVELOPMENT AND PROTOTYPING
Reliability Test Plan
Development
Highly Accelerated Life
Test (HALT) Planning
Environmental Testing
Stress Test Planning
Reliability Demonstration
Failure Analysis & Corrective
Action System (FRACAS)
Vendor Reliability
Auditing/Assessment
Product Qualification
PRODUCTION AND
DEPLOYMENT PHASE
Highly Accelerated
Stress Screening
Environmental
Stress Screening
Vendor Qualification
Warranty Analysis
Hazard Rate/Risk Analysis
Logistics (Depot)
Assessment
Field Reliability Assessment
Data Collection/Analysis
Lifetime Extension
Credentials
As examples of our credentials in RMQ (as well as software engineering, cybersecurity, and knowledge management), we
are the day-to-day operator of the DoDs Center of Excellence in these technologies:
Reliability Information Analysis Center
http://theRIAC.org
http://thecsiac.com
Authors of over 80 publications, papers and presentations and software tools in R&M
SMRP-certified engineers for direct RCM support
ASQ CRE-Certified consulting engineers and instructors in Reliability training
Development of joint government/industry R&M Standards and Handbooks
Performed R&M assessments and analyses for numerous DoD, government, industrial and commercial
customers
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We provide professional high-quality services in all aspects of RMQ, offering an independent unbiased perspective. We
are happy to enter into Nondisclosure Agreements and have a variety of easy-to-use contracting arrangements.
