Reliability Centered Maintenance - Wikipedia, The Free Encyclopedia

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Reliability Centered Maintenance (RCM) is a process tonsure that assets continue to do what their users require in theirresent operating context. [1]

t is generally used to achieve improvements in fields such as thestablishment of safe minimum levels of maintenance, changes toperating procedures and strategies and the establishment of apital maintenance regimes and plans. Successful implementationf RCM will lead to increase in cost effectiveness, machine uptime,nd a greater understanding of the level of risk that therganization is managing.

The late John Moubray, in his industry leading book RCM2 [2],haracterized Reliability-centered Maintenance as a process tostablish the safe minimum levels of maintenance. This description

choed statements in the Nowlan and Heap report from UnitedAirlines.

t is defined by the technical standard SAE JA1011 [3], EvaluationCriteria for RCM Processes, which sets out the minimum criteriahat any process should meet before it can be called RCM. Thistarts with the 7 questions below, worked through in the orderhat they are listed:

1.What is the item supposed to do and its associatedperformance standards?2.In what ways can it fail to provide the required functions?

3.What are the events that cause each failure?4.What happens when each failure occurs?5.In what way does each failure matter?6.What systematic task can be performed proactively to prevent, or to diminish to a satisfactorydegree, the consequences of the failure?7.What must be done if a suitable preventive task cannot be found?

Reliability centered maintenance is an engineering framework that enables the definition of a completemaintenance regime. It regards maintenance as the means to maintain the functions a user may require of machinery in a defined operating context. As a discipline it enables machinery stakeholders to monitor,ssess, predict and generally understand the working of their physical assets. This is embodied in the initialart of the RCM process which is to identify the operating context of the machinery, and write a Failure
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Mode Effects and Criticality Analysis (FMECA). The second part of the analysis is to apply the "RCM logic",which helps determine the appropriate maintenance tasks for the identified failure modes in the FMECA.Once the logic is complete for all elements in the FMECA, the resulting list of maintenance is "packaged", sohat the periodicities of the tasks are rationalised to be called up in work packages; it is important not toestroy the applicability of maintenance in this phase. Lastly, RCM is kept live throughout the "in-service"fe of machinery, where the effectiveness of the maintenance is kept under constant review and adjusted inght of the experience gained.

RCM can be used to create a cost-effective maintenance strategy to address dominant causes of equipment

ailure. It is a systematic approach to defining a routine maintenance program composed of cost-effectiveasks that preserve important functions.

The important functions (of a piece of equipment) to preserve with routine maintenance are identified, theirominant failure modes and causes determined and the consequences of failure ascertained. Levels of riticality are assigned to the consequences of failure. Some functions are not critical and are left to "run toailure" while other functions must be preserved at all cost. Maintenance tasks are selected that address theominant failure causes. This process directly addresses maintenance preventable failures. Failures causedy unlikely events, non-predictable acts of nature, etc. will usually receive no action provided their risk combination of severity and frequency) is trivial (or at least tolerable). When the risk of such failures isery high, RCM encourages (and sometimes mandates) the user to consider changing something which willeduce the risk to a tolerable level.

The result is a maintenance program that focuses scarce economic resources on those items that wouldause the most disruption if they were to fail.

RCM emphasizes the use of Predictive Maintenance (PdM) techniques in addition to traditional preventivemeasures.

Contents

[hide]

1 Historical background2 Basic features3 In use4 Further reading5 See also6 References7 External links

Historical background[ edit ]

The term "reliability-centered maintenance" was first used in public papers [citation needed ] authored by ToMatteson , Stanley Nowlan , Howard Heap , and other senior executives and engineers at United AirlinesUAL) to describe a process used to determine the optimum maintenance requirements for aircraft. Havingeft United Airlines to pursue a consulting career a few months before the publication of the final Nowlan-

Heap report, Matteson received no authorial credit for the work. However, his contributions were substantialnd perhaps indispensable to the document as a whole. The US Department of Defense (DOD) sponsorehe authoring of both a textbook (by UAL) and an evaluation report (by Rand Corporation ) on Reliability

Centered Maintenance, both published in 1978. They brought RCM concepts to the attention of a widerudience. The text book described efforts by commercial airlines and the US Navy in the 1960s and 70s tomprove the reliability of their new jet the Boeing 747 [which? ].
http://en.wikipedia.org/wiki/Planned_maintenancehttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=1http://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://en.wikipedia.org/w/index.php?title=Tom_Matteson&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Tom_Matteson&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Stanley_Nowlan&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Howard_Heap&action=edit&redlink=1http://en.wikipedia.org/wiki/United_Airlineshttp://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://en.wikipedia.org/wiki/Rand_Corporationhttp://en.wikipedia.org/wiki/Wikipedia:Avoid_weasel_wordshttp://en.wikipedia.org/wiki/Wikipedia:Avoid_weasel_wordshttp://en.wikipedia.org/wiki/Rand_Corporationhttp://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://en.wikipedia.org/wiki/United_Airlineshttp://en.wikipedia.org/w/index.php?title=Howard_Heap&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Stanley_Nowlan&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Tom_Matteson&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Tom_Matteson&action=edit&redlink=1http://en.wikipedia.org/wiki/Wikipedia:Citation_neededhttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=1http://en.wikipedia.org/wiki/Planned_maintenance


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The first generation of jet aircraft had a crash rate that would be considered highly alarming today, andoth the Federal Aviation Administration (FAA) and the airlines' senior management felt strong pressure tomprove matters. In the early 1960s, with FAA approval the airlines began to conduct a series of intensivengineering studies on in-service aircraft. The studies proved that the fundamental assumption of designngineers and maintenance plannersthat every airplane and every major component in the airplane (suchs its engines) had a specific "lifetime" of reliable service, after which it had to be replaced (or overhaulen order to prevent failureswas wrong in nearly every specific example in a complex modern jet airliner.

This was one of many astounding discoveries that have revolutionized the managerial discipline of physical

sset management and have been at the base of many developments since this seminal work wasublished. Among some of the paradigm shifts inspired by RCM were:

an understanding that the vast majority of failures are not necessarily linked to the age of the asset(this is often modeled by the "memoryless" exponential probability distribution )changing from efforts to predict life expectancies to trying to manage the process of failurean understanding of the difference between the requirements of assets from a user perspective, andthe design reliability of the assetan understanding of the importance of managing assets on condition (often referred to as conditionmonitoring, condition based maintenance and predictive maintenance)an understanding of four basic routine maintenance taskslinking levels of tolerable risk to maintenance strategy development

Today RCM is defined in the standard SAE JA1011, Evaluation Criteria for Reliability-Centered MaintenanceRCM) Processes. This sets out the minimum criteria for what is, and for what is not, able to be defined as

RCM.

The standard is a watershed event in the ongoing evolution of the discipline of physical asset management.rior to the development of the standard many processes were labeled as RCM even though they were not

rue to the intentions and the principles in the original report that defined the term publicly.

Today companies can use this standard to ensure that the processes, services and software they purchasend implement conforms with what is defined as RCM, ensuring the best possibility of achieving the manyenefits attributable to rigorous application of RCM.

Basic features[ edit ]

The RCM process described in the DOD/UAL report recognized three principal risks from equipment failureshreats

to safety,to operations, andto the maintenance budget.

Modern RCM gives threats to the environment a separate classification, though most forms manage them inhe same way as threats to safety.

RCM offers five principal options among the risk management strategies:

Predictive maintenance tasks,Preventive Restoration or Preventive Replacement maintenance tasks,Detective maintenance tasks,Run-to-Failure, andOne-time changes to the "system" (changes to hardware design, to operations, or to other things).

RCM also offers specific criteria to use when selecting a risk management strategy for a system thatresents a specific risk when it fails. Some are technical in nature (can the proposed task detect the
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ondition it needs to detect? does the equipment actually wear out, with use?). Others are goal-oriented (isreasonably likely that the proposed task-and-task-frequency will reduce the risk to a tolerable level?). The

riteria are often presented in the form of a decision-logic diagram, though this is not intrinsic to the naturef the process.

dentification of Safety Critical Elements (SCE) and maintaining associated pre defined performancetandards is the foundation of asset integrity management.

n use[ edit ]

After being created by the commercial aviation industry, RCM was adopted by the U.S. military (beginningn the mid-1970s) and by the U.S. commercial nuclear power industry (in the 1980s).

tarting in the late 1980s, an independent initiative led by John Moubray corrected some early flaws in therocess, and adapted it for use in the wider industry. John was also responsible for popularizing the

method and for introducing it to much of the industrial community outside of the Aviation industry. (RCM2)

n the two decades since RCM2 was first released, industry has undergone massive change. Increasedconomic pressures and competition, tied with advances in lean thinking and efficiency methods meant thatompanies often struggled to find the people required to carry out an RCM initiative.

At this point in time many methods sprung up that took an approach of reducing the rigour of the RCMpproach. The result was the propagation of many methods that called themselves RCM, yet had little inommon with the original concepts. In some cases these were misleading and inefficient, while in otherases they were even dangerous.

ince each initiative is sponsored by one or more consulting firms eager to help clients use it, there is stillonsiderable disagreement about their relative dangers (or merits). Also there is a tendency for consultingirms to promote a software package as an alternative methodology in place of the knowledge required toerform analyses.

The RCM standard ( SAE JA1011, available from http://www.sae.org ) provides the minimum criteria thatrocesses must comply with if they are to be called RCM.

Although a voluntary standard, it provides a reference for companies looking to implement RCM to ensurehey are getting a process, software package or service that is in line with the original report.

Further reading[ edit ]

2] Standard To Define RCM, (Part 1), Dana Netherton, Maintenance Technology (1998) (Dead links)

3] Standard To Define RCM, (Part 2), Dana Netherton, Maintenance Technology (1998)

4] "Reliability Centered Maintenance - Using RCM Blitz"

See also[ edit ]

Maintenance, repair and operationsTotal Productive Maintenance

References[ edit ]

SAE JA1011, Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes , Society of Automotive Engineers , 01 AUG 1998
http://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=3http://www.sae.org/technical/standards/JA1011_199908http://www.sae.org/http://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=4http://www.mt-online.com/current/06-99mm.htmlhttp://www.mt-online.com/current/08-99mm.htmlhttp://books.mro-zone.com/RCM_Blitz_by_Douglas_Plucknette_p/mm9780982051771.htmhttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=5http://en.wikipedia.org/wiki/Maintenance,_repair_and_operationshttp://en.wikipedia.org/wiki/Total_Productive_Maintenancehttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=6http://en.wikipedia.org/wiki/Society_of_Automotive_Engineershttp://en.wikipedia.org/wiki/Society_of_Automotive_Engineershttp://en.wikipedia.org/wiki/Society_of_Automotive_Engineershttp://en.wikipedia.org/wiki/Society_of_Automotive_Engineershttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=6http://en.wikipedia.org/wiki/Total_Productive_Maintenancehttp://en.wikipedia.org/wiki/Maintenance,_repair_and_operationshttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=5http://books.mro-zone.com/RCM_Blitz_by_Douglas_Plucknette_p/mm9780982051771.htmhttp://www.mt-online.com/current/08-99mm.htmlhttp://www.mt-online.com/current/06-99mm.htmlhttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=4http://www.sae.org/http://www.sae.org/technical/standards/JA1011_199908http://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=3


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SAE JA1012, A Guide to the Reliability-Centered Maintenance (RCM) Standard , Society of AutomotiEngineers , 01 JAN 2002Moubray, John. Reliability-Centered Maintenance. Industrial Press. New York, NY. 1997. ISBN8311-3146-2MSG-3.Maintenance Program Development Document. Air Transport Association, WashingtoD.C. Revision 2, 1993."Nowlan, F. Stanley, and Howard F. Heap. Reliability-Centered Maintenance. Report Number AD-

A066579" (PDF). United States Department of Defense . 1978."MIL-HDBK-2173, Department of Defense Handbook: Reliability-Centered Maintenance (RCM)

Requirements for Naval Aircraft, Weapons Systems, and Support Equipment (S/S BY NAVAIR 00-25-403)" (PDF). United States Department of Defense . 30 JAN 1998."MIL-P-24534A, Military Specification: Planned Maintenance System, Development of MaintenanceRequirement Cards, Maintenance Index Pages, and Associated Documentation" (PDF). Naval SeaSystems Command . 7 MAY 1985."MIL-STD-2173, Military Standard: Reliability-Centered Maintenance (RCM) Requirements for Naval

Aircraft, Weapons Systems, and Support Equipment (S/S By MIL-HDBK-2173)" (PDF). United StatesDepartment of Defense . 21 JAN 1986."MIL-STD-3034, Military Standard: MIL-STD-3034, DEPARTMENT OF DEFENSE STANDARD PRRELIABILITY-CENTERED MAINTENANCE (RCM) PROCESS"(PDF). United States Department of Defense . 21 JAN 2011."NASA Reliability Centered Maintenance (RCM) Guide for Facilities and Collateral Equipment" (PDF)

NASA. FEV 2000."NAVAIR 00-25-403, Guidelines for the Naval Aviation Reliability-Centered Maintenance (RCM)Process)" (PDF). Naval Air Systems Command . 01 JUL 2005."NAVAIR S9081-AB-GIB-010, Reliability-Centered Maintenance (RCM) Handbook)"(PDF). Naval SeSystems Command . 18 APR 2007."TM 5-698-2, Technical Manual: Reliability-Centered Maintenance (RCM) for Command, Control,Communications, Computer, Intelligence, Surveillance, and Reconnaissance (C4ISR) Facilities" (PDFUnited States Army . 06 OCT 2006.

1. ^ [1]

External links[ edit ]

Article:RCM Policy: New Method of Residual Lifetime Prediction According to Item's Actual OperatingState

Article:A Cost-Effective RCM Policy for Periodically Inspected Equipment ItemsWeb Page: Description of RCM and its benefits.

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/rcm-policy-new-method-of-residual-lifetime-prediction-according-to-items-actual-operating-s.htmlhttp://en.wikipedia.org/w/index.php?title=Reliability_centered_maintenance&action=edit&section=7http://www.plant-maintenance.com/RCM-intro.shtmlhttp://en.wikipedia.org/wiki/United_States_Armyhttp://www.everyspec.com/ARMY/TM-Tech-Manual/tm5_698_2_4001/http://www.everyspec.com/ARMY/TM-Tech-Manual/tm5_698_2_4001/http://en.wikipedia.org/wiki/Naval_Sea_Systems_Commandhttp://en.wikipedia.org/wiki/Naval_Sea_Systems_Commandhttp://www.everyspec.com/USN/NAVSEA/S9081-AB-GIB-010_R1_6051/http://en.wikipedia.org/wiki/Naval_Air_Systems_Commandhttp://www.everyspec.com/USN/NAVAIR/NAVAIR_00-25-403_2005_15733/http://www.everyspec.com/USN/NAVAIR/NAVAIR_00-25-403_2005_15733/http://en.wikipedia.org/wiki/NASAhttp://www.everyspec.com/NASA/NASA-General/NASA_RCM_GUIDE_2000_267/http://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://www.everyspec.com/MIL-STD/MIL-STD-3000-9999/MIL-STD-3034_30534/http://www.everyspec.com/MIL-STD/MIL-STD-3000-9999/MIL-STD-3034_30534/http://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://www.everyspec.com/MIL-STD/MIL-STD-2000-2999/MIL-STD-2173_50/http://www.everyspec.com/MIL-STD/MIL-STD-2000-2999/MIL-STD-2173_50/http://en.wikipedia.org/wiki/Naval_Sea_Systems_Commandhttp://en.wikipedia.org/wiki/Naval_Sea_Systems_Commandhttp://www.everyspec.com/MIL-SPECS/MIL-SPECS-MIL-P/MIL-P-24534A_6052/http://www.everyspec.com/MIL-SPECS/MIL-SPECS-MIL-P/MIL-P-24534A_6052/http://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://www.everyspec.com/MIL-HDBK/MIL-HDBK-2000-2999/MIL-HDBK-2173_15046/http://www.everyspec.com/MIL-HDBK/MIL-HDBK-2000-2999/MIL-HDBK-2173_15046/http://www.everyspec.com/MIL-HDBK/MIL-HDBK-2000-2999/MIL-HDBK-2173_15046/http://en.wikipedia.org/wiki/United_States_Department_of_Defensehttp://www.dtic.mil/cgi-bin/GetTRDoc?Location=U2&doc=GetTRDoc.pdf&AD=ADA066579http://www.dtic.mil/cgi-bin/GetTRDoc?Location=U2&doc=GetTRDoc.pdf&AD=ADA066579http://en.wikipedia.org/wiki/Special:BookSources/0831131462http://en.wikipedia.org/wiki/Special:BookSources/0831131462http://en.wikipedia.org/wiki/Society_of_Automotive_Engineershttp://en.wikipedia.org/wiki/Society_of_Automotive_Engineers


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