" Copyright 2002, Information Spectrum, Inc. All Rights Reserved." RCM DECISION LOGIC Module 5 UNIT II RCM PROCESS

"Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC

Module 5Module 5

UNIT IIUNIT II

RCM PROCESSRCM PROCESSRCM PROCESSRCM PROCESS

IntroductioIntroductionn


Module Preview:Module Preview:Module Preview:Module Preview:

IntroductionIntroductionIntroductionIntroduction

RCM Decision LogicRCM Decision LogicRCM Decision LogicRCM Decision Logic


Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences

Task EvaluationTask EvaluationTask EvaluationTask Evaluation

Task SelectionTask SelectionTask SelectionTask Selection

Review and SummaryReview and SummaryReview and SummaryReview and Summary

Module Objectives:Module Objectives:Module Objectives:Module Objectives: IntroductioIntroductionn


1. Describe the RCM Decision Logic1. Describe the RCM Decision Logic

2.2. Identify the four types of failure Identify the four types of failure consequences that make up the branches consequences that make up the branches of the RCM Decision Logic treeof the RCM Decision Logic tree

3.3. Describe the RCM Task Evaluation ProcessDescribe the RCM Task Evaluation Process


Module Objectives:Module Objectives:Module Objectives:Module Objectives: IntroductioIntroductionn


4. Identify the following task types:4. Identify the following task types:

ServicingServicing

LubricationLubrication

On ConditionOn Condition

Hard TimeHard Time

Failure FindingFailure Finding

5. Introduce the RCM Task Selection Process5. Introduce the RCM Task Selection Process

end


1. Identify Team and responsibilities 4. Identify and document Review Process2. Identify analysis items 5. Orientation/Training3. Prioritize Items 6. Ground Rules and Assumptions

PLANNING AND PREPARATION

ANALYSIS

RCM ProcessRCM ProcessRCM ProcessRCM Process

AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan

AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan

MaintenanceMaintenanceRequirementsRequirements

MaintenanceMaintenanceRequirementsRequirements

Maintenance Maintenance ProgramProgram

Maintenance Maintenance ProgramProgram

DataDataDataData

1. Equipment Kick-off Meeting2. Initial Data Gathering3. Hardware Partition4. Function5. Functional Failure6. Failure Mode7. Failure Effects8. Failure Consequences9. Task Evaluation10. Task Selection

1. Package Maintenance Task2. Implement Other Actions

ResultsResults

IMPLEMENT RESULTS

1. Emergent Issues2. Age Exploration3. Hardware Changes4. Trend/degrader analysis5. Document Reviews

SUSTAIN

RCM Decision LogicRCM Decision LogicRCM Decision LogicRCM Decision Logic

RCM DECISION LOGICRCM DECISION LOGIC

Process used to determine what action should Process used to determine what action should be taken to eliminate or lessen the be taken to eliminate or lessen the consequences that result from the occurrence consequences that result from the occurrence of a failure modeof a failure mode

RCM Decision LogicRCM Decision LogicRCM Decision LogicRCM Decision LogicPurpose:Purpose:Purpose:Purpose:


Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?

YESEvident

NOHidden

Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety?

Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety?

YES

EvidentSafety/

Environment

YES

HiddenSafety/

Environment

NO

HiddenEconomic/

Operational

Analyze Options:

S, L, OC, HT,Other Action

Analyze Options:

S, L, OC, HT,No PM,

Other Action

Analyze Options:

S, L, OC, HT, FF,No PM,

Other Action

Analyze Options:

S, L, OC, HT, FF,Other Action

NO

EvidentEconomic/

Operational

Select BEST OPTION


YESYESEvidentEvident

NONOHiddenHidden

Does failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation?

Does hidden failure mode in combination with second failure/event cause function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation?

YESYES

EvidentEvidentSafety/Safety/

EnvironmentEnvironment

YESYES

HiddenHiddenSafety/Safety/

EnvironmentEnvironment

NONO

HiddenHiddenEconomic/Economic/

OperationalOperational

Analyze Options:


Analyze Options:

S, L, OC, HT,No PM,

Other Action

Analyze Options:


Other Action

Analyze Options:


NONO

EvidentEvidentEconomic/Economic/

OperationalOperational

Select BEST OPTION


Consequences of FailureConsequences of Failure

FailureFailure ConsequencesConsequencesFailureFailure ConsequencesConsequencesUse of :Use of :Use of :Use of :

Failure consequences:Failure consequences: the impact that the impact that the effects of a failure have on safety, the effects of a failure have on safety, operations, and the environment … and operations, and the environment … and whether the failure is evident to the whether the failure is evident to the operatoroperator

When the failure consequences warrant When the failure consequences warrant attention, the goal of RCM is to control the attention, the goal of RCM is to control the consequences by:consequences by:

•avoiding them (reducing their frequency) avoiding them (reducing their frequency) •reducing their severityreducing their severity



• Failure consequences are categorized Failure consequences are categorized in two steps:in two steps:

• Hidden or EvidentHidden or Evident• Safety/Environment or Safety/Environment or

Operational/EconomicOperational/Economic

Identifying:Identifying:Identifying:Identifying:


Identifying:Identifying:Identifying:Identifying: Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences

Failure Consequences Step 1:Failure Consequences Step 1:

• Evident FailureEvident Failure: : A failure that, by itself, A failure that, by itself, is is apparent apparent to the operator under normal to the operator under normal circumstancescircumstances

• Hidden FailureHidden Failure: : A failure that isA failure that is not not apparentapparent to the operator under normal to the operator under normal circumstancescircumstances


Question 1:Question 1:Question 1:Question 1:

Is the functional failure or effect of the Is the functional failure or effect of the failure mode, on its own, EVIDENT to the failure mode, on its own, EVIDENT to the OPERATOR while performing NORMAL OPERATOR while performing NORMAL DUTIES?DUTIES?

EvidentEvident HiddenHidden

Does the failure mode cause a Does the failure mode cause a function loss or secondary damage function loss or secondary damage that could have an adverse effect that could have an adverse effect on operating safety or the on operating safety or the environment?environment?

YESYES NONO

EvidentEvidentSafety/Safety/EnvironmentEnvironment

HiddenHiddenSafety/Safety/EnvironmentEnvironment

EvidentEvidentEconomic/Economic/OperationalOperational

HiddenHiddenEconomic/Economic/OperationalOperational

YESYES NONO NONO YESYES

Does the occurrence of the hidden failure Does the occurrence of the hidden failure mode in combination with a second mode in combination with a second failurefailure /event cause a function loss or /event cause a function loss or secondary secondary damage that could have an adverse damage that could have an adverse effect on operating safety or the effect on operating safety or the environment?environment?

Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences


EVIDENT - EVIDENT - Apparent to Apparent to operator without special operator without special monitoring.monitoring.

OPERATOR – OPERATOR – Crew/Equipment OperatorCrew/Equipment Operator

#2

#1


The evident and hidden The evident and hidden groups are further divided groups are further divided based on failure effects:based on failure effects:

• Safety Safety • EnvironmentEnvironment• Operations Operations • EconomicsEconomics

2 Fly-ins2 Fly-ins

Failure Consequences Step 2:Failure Consequences Step 2:

Identifying:Identifying:Identifying:Identifying:


Is the functional failure or effect of the Is the functional failure or effect of the failure mode, on its own, evident to the failure mode, on its own, evident to the operator while performing normal duties?operator while performing normal duties?



YESYES NONO






Does the occurrence of the hidden Does the occurrence of the hidden failure mode/event cause a failure mode/event cause a function loss or secondary damage function loss or secondary damage that could have an adverse effect that could have an adverse effect on operating safety or the on operating safety or the environment?environment?

Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences Question 2:Question 2:Question 2:Question 2:


Is the functional failure or effect of the Is the functional failure or effect of the failure mode, on its own, evident to the failure mode, on its own, evident to the operator while performing normal duties?operator while performing normal duties?



YESYES NONO






Does the occurrence of the hidden failure Does the occurrence of the hidden failure mode in combination with a second mode in combination with a second failure/event cause a function loss or failure/event cause a function loss or secondary damage that could have an secondary damage that could have an adverse effect on operating safety or the adverse effect on operating safety or the environment?environment?

Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences Question 3:Question 3:Question 3:Question 3:



In summary, failures are In summary, failures are categorized by consequences.categorized by consequences.

RCM uses four categories:RCM uses four categories:• Evident Safety/Environmental Evident Safety/Environmental

• Hidden Safety/EnvironmentalHidden Safety/Environmental

• Evident Economical/OperationalEvident Economical/Operational

• Hidden Economical/OperationalHidden Economical/Operational

Categories:Categories:Categories:Categories:



Evident failure:Evident failure:• Eliminate/reduce the consequence of Eliminate/reduce the consequence of

single failuresingle failure

Hidden failure:Hidden failure:• Eliminate/reduce consequences of Eliminate/reduce consequences of

multiple failuremultiple failure• Eliminate/reduce economic consequence Eliminate/reduce economic consequence

of single failureof single failure

A A Multiple FailureMultiple Failure is a c is a combination of a ombination of a hidden failure plus a second failure or other hidden failure plus a second failure or other event that makes the hidden failure evidentevent that makes the hidden failure evident

Managing:Managing:Managing:Managing:



Safety/Environmental failure:Safety/Environmental failure:• Must prevent the consequences of Must prevent the consequences of

failurefailure

Economic/Operational failure:Economic/Operational failure:• Prevent or allow failurePrevent or allow failure

Summary: RCM decision logic process Summary: RCM decision logic process provides the appropriate management provides the appropriate management strategies for each consequence categorystrategies for each consequence category

Managing:Managing:Managing:Managing:


EVIDENTEVIDENT HIDDENHIDDEN

Safety/Safety/EnvironmentEnvironment

Economic/Economic/OperationalOperational

Economic/Economic/OperationalOperational

Safety/Safety/EnvironmentEnvironment

Consequences Consequences Branches:Branches:

Consequences Consequences Branches:Branches:

Analyze Analyze Options:Options:

S, L, OC, HT,S, L, OC, HT,Other ActionOther Action


S, L, OC, HT,S, L, OC, HT,No PM,No PM,

Other ActionOther Action

Analyze Options:Analyze Options:

S, L, OC, HT, FF,S, L, OC, HT, FF,No PM,No PM,

Other ActionOther Action


S, L, OC, HT, FF,S, L, OC, HT, FF,Other ActionOther Action

Select BEST OPTIONSelect BEST OPTION

Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences


Task EvaluationTask Evaluation


Purpose:Purpose:Purpose:Purpose:

To determine what actions can be taken to To determine what actions can be taken to prevent a failure mode from occurring; or, if not prevent a failure mode from occurring; or, if not prevented, to lessen its effects to an acceptable prevented, to lessen its effects to an acceptable level.level.

Task Task EvaluationEvaluation



EVIDENT HIDDEN

Safety/Environment

Economic/Operational

Economic/Operational

Safety/Environment

Analyze Options:


Analyze Options:

S, L, OC, HT,No PM,

Other Action

Analyze Options:


Other Action

Analyze Options:


Select BEST OPTION

Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks: Task EvaluationTask EvaluationTask EvaluationTask Evaluation


Servicing:Servicing:Servicing:Servicing:

The replenishment of consumable materialsthat are depleted during normal operations.

The replenishment of consumable materialsthat are depleted during normal operations.



Lubrication:Lubrication:Lubrication:Lubrication:

The scheduled lubrication of a component The scheduled lubrication of a component (usually based on the manufacture’s (usually based on the manufacture’s recommendations) where the item’s design recommendations) where the item’s design requires a non-permanentrequires a non-permanent lubricant for proper lubricant for proper operationoperation



On-ConditionOn-Condition Task EvaluationTask EvaluationTask EvaluationTask Evaluation

Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure.

Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure.


Hard Time Task:Hard Time Task:Hard Time Task:Hard Time Task:

Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure.

Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure.



Failure Finding:Failure Finding:Failure Finding:Failure Finding:

A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.

A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.

Task EvaluationTask Evaluation


5 Fly-ins

Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks: Task Task EvaluationEvaluation

Task Task EvaluationEvaluation• S (Servicing Task)S (Servicing Task) - Replenishment of consumable - Replenishment of consumable

materials depleted during normal operationsmaterials depleted during normal operations• L (Lubrication Task)L (Lubrication Task) - Replacement of a lubricant - Replacement of a lubricant

based on manufacturer’s predicted or measured life based on manufacturer’s predicted or measured life of the lubricantof the lubricant

• OC (On Condition Task)OC (On Condition Task) - Periodic or continuous - Periodic or continuous inspection designed to detect a potential failure inspection designed to detect a potential failure condition prior to functional failurecondition prior to functional failure

• HT (Hard Time Task)HT (Hard Time Task) - Scheduled removal of an item - Scheduled removal of an item or a restorative action at some specified age limit or a restorative action at some specified age limit to prevent its functional failureto prevent its functional failure

• FF (Failure Finding Task)FF (Failure Finding Task) - - A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.


Other Action Warranted:Other Action Warranted:Other Action Warranted:Other Action Warranted:

Other Action: Usually a one time action, other Other Action: Usually a one time action, other than PM, that will effectively reduce the than PM, that will effectively reduce the consequences of failure to an acceptable levelconsequences of failure to an acceptable level

• Item redesignItem redesign

• Change in an operational or maintenance Change in an operational or maintenance procedureprocedure

• Operating restrictionsOperating restrictions

• Etc.Etc.



Other Action Warranted:Other Action Warranted:Other Action Warranted:Other Action Warranted:

Consider when Consider when

• No acceptable PM task can be found for No acceptable PM task can be found for safety/environmental consequence failures safety/environmental consequence failures

• Other Action is preferable to PM and run to Other Action is preferable to PM and run to failurefailure

• Other action, in combination with PM, will Other action, in combination with PM, will beneficially reduce consequences or beneficially reduce consequences or frequency of failurefrequency of failure



RCM Decision Logic RCM Decision Logic Results:Results:

RCM Decision Logic RCM Decision Logic Results:Results:

Once a failure mode is subjected to the RCM Once a failure mode is subjected to the RCM Decision Logic, at least one of the following Decision Logic, at least one of the following outcomes will result:outcomes will result:

• PM RequiredPM Required

• No PM RequiredNo PM Required

• Other Action WarrantedOther Action Warranted




Task SelectionTask Selection



YESEvident

NOHidden

Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety?

Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety?

YES

EvidentSafety/

Environment

YES

HiddenSafety/

Environment

NO

HiddenEconomic/

Operational

Analyze Options:


Analyze Options:

S, L, OC, HT,No PM,

Other Action

Analyze Options:


Other Action

Analyze Options:


NO

EvidentEconomic/

Operational

Select BEST OPTION


YESEvident

NOHidden

Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment?

Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment?

YES

EvidentSafety/

Environment

YES

HiddenSafety/

Environment

NO

HiddenEconomic/

Operational

Analyze Options:


Analyze Options:

S, L, OC, HT,No PM,

Other Action

Analyze Options:


Other Action

Analyze Options:


NO

EvidentEconomic/

Operational

Select BEST OPTION

Selection Selection Process:Process:

Selection Selection Process:Process:

One or more PM tasks may prevent or reduce One or more PM tasks may prevent or reduce the probability of failure to an acceptable level. the probability of failure to an acceptable level. These tasks along with... These tasks along with...

• a decision to allow the failure mode to a decision to allow the failure mode to occur (no PM)occur (no PM)

• some “other action”... some “other action”...

… … form a pool of options from which solutions form a pool of options from which solutions can be generated.can be generated.

Task SelectionTask SelectionTask SelectionTask Selection


Review and Review and SummarySummary

Review and Review and SummarySummary

• IntroductionIntroduction• IntroductionIntroduction

• Learning ObjectivesLearning Objectives• RCM Decision LogicRCM Decision Logic• RCM Decision LogicRCM Decision Logic

• Task EvaluationTask Evaluation• Task EvaluationTask Evaluation

• Task SelectionTask Selection• Task SelectionTask Selection

7 Fly-ins


• Module ObjectiveModule Objective• Module ObjectiveModule Objective

End of Module up next……..

UNIT IIIRCM Software Review

End of Module up next……..

UNIT IIIRCM Software Review

Documents

" Copyright 2002, Information Spectrum, Inc. All Rights Reserved." RCM DECISION LOGIC Module 5 UNIT II RCM PROCESS