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Reliability Centered MaintenanceFAG
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BREAKDOWN / FAILURE RATE of EQUIPMENT
Breakdown: a failure of one equipment to do its function
Every equipment in every industry typically follow a so-called
bath-tub or wear-out curve
A good maintenance program will extend the minimum breakdown
period
How to create a good maintenance program?
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In RCM we trust!The purpose of RCM:
Identify the techniques/methods/policies that preserve the
function of an asset in its operating (not design) context
Preserve the function, not just maintain the equipment
With RCM, these items are ensured:
The right maintenance is performed (TASK),
at the right time (INTERVAL/PERIOD),
by the right people (CRAFT),
in the right way (CONDITION, PERMIT, etc),
and with the right training, skills, tools, and spare parts
RCM means less corrective maintenance, more proactive
approach
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How to get RCM right?To get the 5 items right, there are 7
questions that need to be asked to each equipment:
What are the desired standards of performance of the
assets/equipment in the present operating context? [FUNCTION]
In what ways can it fail to fulfil its functions [FUNCTIONAL
FAILURES]
What causes each functional failures? [FAILURE MODES]
What is the effect of the failures? [FAILURE EFFECT]
In what way does each failures matter? [FAILURE
CONSEQUENCES]
What should be done to predict or prevent each failure?
[PROACTIVE TASKS and TASKS INTERVAL]
What should be done if a suitable proactive task can not be
found? [DEFAULT ACTIONS]
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Maintenance Activity and its Cost
At this stage a valuable RCFA & FMEA information could be
gathered
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Maintenance Activity in RCM and Current Condition
RCM
Reactive Preventive Predictive Proactive
1. Small items 2. Non-critical 3. Inconsequential 4. Unlikely to
fail 5. Multiple
Redundancy
1. Subject to wear-out
2. Consumable Replacement
3. Failure pattern known
1. Random failure pattern
2. Not subject to wear
3. Induced failures
1. RCFA 2. FMECA 3. Age extending
program}1. Our maintenance system
accommodate for these activity. Still needs a lot of improvement
in Job Plan, reporting, and reviewing
2. Operator Technician Look-Listen-Feel able to identify initial
stage of failure
}1. Some of our CM came from PdM
follow up 2. But PdM is not yet implemented
properly. Tools, point of measurement, results & trending
should be easily accessible by CBM Engineer
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1. There are improvement to increase reliability.
2. Improvement (engineering or maint. program) by RCFA and FMECA
are not yet a culture
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How to get RCM right? - contd
Planning & Preparation
Identify Teams & Resposibilities
Identify Assets or Equipments
Prioritizing Items
Identify and Document Review
Set Ground Rules & Assumption
Analysis
Initial Data Gathering
Equipment Partition
Functions
Functional Failure
Failure Modes
Failure Effects
Failure Consequences
Job Plan Evaluation
Job Plan Selection
} FMECA needs multi -discipline experts
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How to get RCM right? - contd
Implement Results
Job Plan gap identified
Package Maintenance Job Plan input
Incorporate PdM activity & reporting to Maintenance
System
Implement other important actions
Sustain
Reliability & Maintainability Data Analysis
Age Extension Program
Hardware/Equipment Changes
Trending of Degradation
Document Review
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Is This The End of a Tunnel?
In the Sustained Maintenance Planning scheme, RCM process only
occupied a small (but important) amount of area
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Only a Step to Reach Reliability EAM Organization
RCM Process increase our maturity in this area:
