Reliability Centered Maintenance (RCM)

Reliability Centered Maintenance (RCM)

Arrelic end-to-end Reliability Management allows you to;
Identify and rectify equipment problems before they happen, Reduce maintenance costs and unplanned downtime.

RCM is used to develop scheduled maintenance plans in an efficient and cost-effective manner that will provide an acceptable level of operability and risk. It focuses on processes and systems to reduce the overall cost to maintain and operate assets. Arrelic Consulting assists industries in integrating assets and increasing return on investment by enhanced asset performance and reliability.

Maintenance strategy development and optimisation through Critical Asset Ranking, RCM Approach and cost benefit analysis ensures you the best maintenance plan.

Reliability Centered Maintenance answers following questions:

  • Which assets are critical and can cause significant downtime?
  • What failure modes and effects are likely?
  • What is the optimum maintenance strategy?
  • What is the most effective grouping and frequency of tasks?
  • What tasks are to be performed on each job?

Know more about Reliability Centered Maintenance

Benefits:

5 Key Benefits:

An Effective Reliability Management can improve the Operating Profit Margin by 15 – 35 %*

Enhance Asset Performance
Ensure the optimal asset performance by assuring asset integrity, increasing asset availability, optimizing expenses, increasing capital efficiency and improving personal and process safety.

Step to ISO 55001
ISO 55001 is a framework for an asset management system that will help your business to pro-actively manage the lifecycle of your assets, from acquisition to decommission. Our approach to optimize asset performance will provide a step to achieve ISO 55001 standard.

Optimize Maintenance Strategy and Improve Productivity
Evolve form time based maintenance to predictive maintenance, improving availability and reliability.

Reduce Downtime and Operational Costs
Focus resources where you need, reduce overtime and cost of parts. Our approach to identify and rectify errors before they happen allows you to reduce downtime, eliminate major costs due to defects and incorporate reliability culture. These can significantly improve the overall performance (OEE) and profitability of the organization.

Mitigate Risk to your people
Reduce the risk due to equipment problems to your employees.

* Effectiveness depends upon many internal and external factors.

Basic Process of RCM

Although there is a great deal of variation in the application of RCM, most procedures include some or all of the following steps.

  • Prepare for the Analysis

    As with almost any project, some preliminary work will be required to prepare for the RCM analysis. Some important up-front activities include assembling an appropriate cross-functional team, making sure that all members of the analysis team understand and accept the ground rules and conditions of the analysis (e.g., scope of the analysis, definition of "failure," etc.), gathering and reviewing relevant documentation, etc.

  • Select the Equipment to Be Analyzed

    Because RCM analysis requires an investment of time and resources, the organization may wish to focus analysis resources on selected pieces of equipment, based on safety, legal, economic and other considerations. Selection Questions and Criticality Factors are two methods of equipment selection that are commonly employed.

    • The Selection Questions method consists of a set of Yes/No questions that are designed to identify whether RCM analysis is indicated for a particular piece of equipment. For example, there are four questions in the MSG-3 guideline used to develop initial scheduled maintenance plans for the aircraft industry. If the analyst answers Yes to at least one of the questions, then detailed analysis is indicated for the equipment.
    • The Criticality Factors method consists of a set of factors designed to evaluate the criticality of the equipment in terms of safety, maintenance, operations, environmental impact, quality control, etc. Each factor is rated according to a pre-defined scale (e.g., 1 to 5 or 1 to 10) where higher ratings indicate higher criticality. The equipment’s criticality value can then be used as a ranking and/or as a threshold.

    Other methods, such as Pareto analysis of equipment based on downtime, unreliability or other relevant metrics, may also be applied. Whichever method (or combination of methods) is selected, the goal is to focus RCM analysis resources on the equipment that will provide the maximum benefit to the organization in terms of safety, legal, operational, economic and related priorities.

  • Identify Functions and Potential Functional Failures

    One of the primary tenets of the Reliability Centered Maintenance approach is that maintenance activities should be focused toward preserving equipment functionality. Therefore, it follows that the first step in analyzing a particular piece of equipment is to identify the function(s) it is intended to perform. Many RCM references recommend including specific performance requirements in function descriptions, which will help to specifically identify functional failures.

    Functional failures describe ways that the equipment may fail to perform its intended functions. This may include failure to perform a function, poor performance of a function, over-performance of a function, performing an unintended function, etc. As mentioned above, the performance limits that have been identified for the function may provide a guide to the functional failure description. For example, "Provides hydraulic pressure of more than 3200 psi," "Provides hydraulic pressure of less than 2800 psi," etc.

  • Identify and Evaluate (Categorize) the Effects of Failure

    Identifying and evaluating the effects of failure will help the team to prioritize and choose the appropriate maintenance strategy to address a potential failure. Many RCM references contain logic diagrams that can be used to evaluate and categorize the effects of failure. These logic structures often differentiate evident vs. hidden effects and whether the issue has safety, environmental, operational and/or economic consequences.

  • Identify Causes of Failure

    The cause of failure (sometimes also called failure mode) represents the specific cause of the functional failure at the actionable level (i.e., the level at which it will be possible to apply a maintenance strategy to address the potential failure). This determination is based on engineering judgment and relies on the team’s experience and skill with the RCM analysis process.

    The recommendation states that "failure modes should be described in enough detail for it to be possible to select an appropriate failure management policy, but not in so much detail that excessive amounts of time are wasted on the analysis process itself."

  • Select Maintenance Tasks

    Once you have identified the functions that equipment is intended to perform, the ways that it might fail to perform those intended functions and evaluated the consequences of these failures; the next step is to define the appropriate maintenance strategy for the equipment. The RCM analysis team’s decision of which strategy (or strategies) to employ for each potential failure may be based on judgment/experience, a pre-defined logic diagram (connected to the failure effect categorization), cost comparisons or some combination of factors.

    Many RCM guidelines include task selection logic diagrams based on the Failure Effect Categorization. When safety is not an issue, another is to compare normalized cost values for the available maintenance strategies and select the maintenance task that provides the desired level of availability for the minimum cost.

  • Maintenance Packaging

    Once the appropriate schedule maintenance tasks have been identified, the final step is to package them into a workable maintenance plan. This may involve choosing time intervals at which groups of tasks can be carried out most effectively and efficiently.

Let’s talk