RELIABILITY CENTRED MAINTENANCE (RCM)

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RELIABILITY CENTRED MAINTENANCE (RCM) Application within RCAF and Implementation in OmegaPS Mike Martin

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RELIABILITY CENTRED MAINTENANCE (RCM). Application within RCAF and Implementation in OmegaPS. Mike Martin. BRIEFING OUTLINE. Maintenance Environment within RCAF RCM Process (MSG-3) Principles of RCM Significant Item Selection Functional FMEA Level 1 & 2 Decision Logic - PowerPoint PPT Presentation

Transcript of RELIABILITY CENTRED MAINTENANCE (RCM)

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RELIABILITY CENTRED MAINTENANCE (RCM)

Application within RCAF and Implementation in OmegaPS

Mike Martin

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BRIEFING OUTLINE

Maintenance Environment within RCAF

RCM Process (MSG-3)– Principles of RCM– Significant Item Selection– Functional FMEA– Level 1 & 2 Decision Logic– Task Assignment and Packaging

Implementation in OmegaPS (FRCM)

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MAINTENANCE ENVIROMENT WITHIN RCAF

• Maintenance Program part of Design• Changes tightly regulated• Conduct of Maintenance on aircraft /

equipment recorded and controlled• Support to Legacy fleets becoming more

challenging

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WHAT IS RCM?A Definition:– RCM is a structured process to identify the appropriate level

of preventive maintenance for an item to:• Retain inherent levels of performance, reliability and

safety• Minimize cost of maintenance and failures over the life

cyclePrimary Objectives:– Ensure safety through PM actions; when PM cannot

effectively ensure safety, redesign is mandatory– When safety is not a concern, preserve functionality in the

most economical manner with the least impact on Operations

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WHY DO RCM?New Programs:

– Requirement of design (ICAs)– Identify APPLICABLE and EFFECTIVE scheduled

maintenance tasks– Initial programs conservative and generic

Legacy Programs:– Able to modify generic programs to suit

environment and fleet performance– Structured, disciplined approach to substantiating

proposed Design Changes

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FLAVOURS OF RCM

ATA/MSG-3 (***)RCM II

NAVAIR 00-25-403 NAVSEA S9081-AB-GIB-010

DEF STAN 02-45Etc

If any question about whether or not a process meets RCM requirements consult:

SAE JA1011 – Evaluation Criteria for RCM Processes

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STEPS TO PERFORM RCM

Step 1: Identify MSIStep 2: Perform Functional FMEAStep 3: Apply MSG-3 Decision Logic

Level 1 – Failure Effect Code

Level 2 – Task IdentificationStep 4: Package Maintenance Tasks

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MAINTENANCE SIGNIFICANT ITEMS(MSIs)

– Objective of MSI selection: select appropriate systems / components for analysis

– Why be selective?• A/C equipment and systems have many components and

parts• Analysis of every component on an aircraft would be

unrealistically costly and time consuming• Failure of many items have no immediate impact on the

a/c as a whole– RCM derived maintenance program directs tasks

where they matter – at Significant Items

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– Partition equipment into major functional areas

– Top-down approach; identify items at highest manageable level

– Item is MSI if failure could:• adversely effect safety• Have major operational or economic consequences• Be undetectable during normal operations

– If in doubt, item should be selected as an MSI

STEP 1 – IDENTIFY MSIs

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PARTITION EQUIPMENT

WEAPON SYSTEM

SYSTEM

SUB SYSTEM

SYSTEM

SUB SYSTEM SUB SYSTEM

LRU LRU LRULRU

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ITEM FROM ECIR

DOES ITEM HAVE CURRENT TASK OTHER THAN REMOVE FOR ACCESS?

IS ITEM STRUCTURE ?RETAIN TASK

YES YES

IDENTIFY AS NON-MSI

NO

MSG-3ANALYSIS

COULD FAILURE BE HIDDEN OR NOT LIKELY TO BE DETECTED BY THE OPERATING CREW DURING

NORMAL DUTIES?

COULD FAILURE AFFECT SAFETY(ON GROUND OR IN FLIGHT) INCLUDING SAFETY/EMERGENCY

SYSTEMS OR EQUIPMENT?

COULD FAILURE HAVE A SIGNIFICANT ECONOMIC IMPACT?

COULD FAILURE HAVE A SIGNIFICANT OPERATIONAL IMPACT?

YES

YES

YES

YES

NO

NO

NO

NO

IDENTIFY AS NON-MSI

NO

NO

MSI 1

MSI 7

MSI 3

MSI 2

MSI 6

MSI 5

MSI 4

IDENTIFY AS MSI

YES

DOES STRUCTURE ITEM HAVE CURRENT TASK OTHER THAN REMOVE

FOR ACCESS?

MSI SELECTION DECISION LOGIC

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INDENTIFY FUNCTIONWhat are the normal characteristics of the

MSI?

How does the MSI fail to perform this

function?

ARE THERE ADDITIONAL FUNCTIONS

?

YES

IDENTIFY FUNCTIONALFAILURE

ARE THERE ADDITIONAL

FUNCTIONALFAILURES

?

YES

FOR EACH FUNCTION

NO

INCREMENT IDENTIFICATION FOR

EACH FUNCTION(eg. 1,2…)

INCREMENT IDENTIFICATION FOR EACH FUNCTIONAL

FAILURE(eg. 1A, 1B …)

FOR EACH FUNCTIONALFAILURE

IDENTIFY FUNCTIONAL FAILUREEFFECT

What happens when this functional failure

occurs?

IDENTIFY FUNCTIONAL FAILURECAUSE(S)

NO

ARE THERE ADDITIONAL

FAILURE EFFECTS?

INCREMENT IDENTIFICATION

FOR EACH FUNCTIONAL

FAILURE EFFECT(eg. 1A1, 1A2 …)

YES

FOR EACH FAILURE EFFECT

ARE THERE ADDITIONAL

FAILURE CAUSES?

INCREMENT IDENTIFICATION

FOR EACH FAILURECAUSE

(eg. 1A1A, 1A1B …)

YES

END FMEA

NO

NO

STEP 2 - FUNCTIONAL FMEA

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RESULTS OF FMEA

For each MSI:- List of High Level Functions

For each Function:- List of Functional Failures

For each Functional Failure:- List of Failure Effects

For each Failure Effect:- List of Components which cause this

Functional Failure/Failure Effect to Occur

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EXAMPLE OF FMEA

EXAMPLE ONLY

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STEP 3 – APPLY MSG-3 DECISION LOGIC

LEVEL 1 – Identification of Functional failure Effect (FEC)

LEVEL 2 – Identification of APPLICABLE and EFFECTIVE Preventive Maintenance Task

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MSG-3 LEVEL 1 & 2 DECISION LOGIC

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LEVEL 1 DECISION LOGIC

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LEVEL 2 DECISION LOGICIS A LUBRICATION OR SERVICING TASK APPLICABLE & EFFECTIVE?

5A

LUBRICATION/SERVICING

INSPECTION/FUNCTIONAL CHECK

RESTORATION

DISCARD

IS DISCARD TASK TO AVOID FAILURES OR REDUCE THE FAILURE RATE

APPLICABLE & EFFECTIVE?

5D

IS RESTORATION TASK TO REDUCE FAILURE RATE APPLICABLE &

EFFECTIVE?

5C

IS AN INSPECTION OR FUNCTIONAL CHECK TO DETECT DEGREDATION OF FUNCTION APPLICABLE & EFFECTIVE?

5B

IS THERE A TASK OR COMBINATION OF TASKS APPLICABLE & EFFECTIVE?

5E

NOYES

YES

YES

YES

YES

NO

NO

NO

NO

REDESIGN IS MANDATORY

TASK/COMBINATION MOST EFFECTIVE MUST BE DONE

IS A LUBRICATION OR SERVICING TASK APPLICABLE & EFFECTIVE?

6A

LUBRICATION/SERVICING

INSPECTION/FUNCTIONAL CHECK

RESTORATION

DISCARD

IS DISCARD TASK TO AVOID FAILURES OR REDUCE THE FAILURE RATE

APPLICABLE & EFFECTIVE?

6D

IS RESTORATION TASK TO REDUCE FAILURE RATE APPLICABLE &

EFFECTIVE?

6C

IS AN INSPECTION OR FUNCTIONAL CHECK TO DETECT DEGREDATION OF FUNCTION APPLICABLE & EFFECTIVE?

6B

NOYES

YES

YES

YES

NO

NO

NO

REDESIGN MAY BE DESIREABLE

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EXAMPLE OF LEVEL 1 / 2

EXAMPLE

ONLY

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STEP 4 – TASK PACKAGING

Select Significant Intervals

Fit Others into this interval or multiples

Group Individual Tasks Together By:- Location- Trade- Complexity- Frequency

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SAMPLE INSPECTION CARD

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Inspection Tasks (4 trades)

TYPICAL INSPECTION

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CURRENT TOOLS

• AEPM Performa– ADAM data from the field– Extracted into Excel files

• Maintenance Analyzer (ATESS)– Access Database

• MSI• FMEA• Level 1 / 2 analysis

• Audit– MS Excel

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CURRENT TOOLS

• Card Deck– Access Database– MS Word Templates– Contactor Database (IETM)– ????

• Scheduling / Planning– MS Project / MS Excel– Paper– ????

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FUNCTIONAL RCM (FRCM)IN OmegaPS

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FRCM MODULE

• Create FUNCTIONAL structure• MANAGE analysis assignments• Perform FMEA• Audit FMEA • Perform Level 1 / Level 2 analysis• Assign Task and Interval• Audit Level 1 / Level 2 and Task analysis

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CREATE FUNCTIONAL STRUCTURE

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SELECT FUNCTIONAL RCM MODULE

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FUNCTIONAL TREE STRUCTURE

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MANAGER

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DEVELOP FMEA

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OmegaPS FMEA Worksheet

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LEVEL 1 ANALYSIS

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LEVEL 2 ANALYSIS

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LEVEL 1 / LEVEL 2 REPORT

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TASK / INTERVAL IDENTIFICATION

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POTENTIAL OmegaPS MODULE INTEGRATION

FRCM

ANALYZER

PoM

PUBLISHER

LORA

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Questions?