Reliability Centered Maintenance-Gary

Reliability Centered Maintenance June 9, 2011 Gary Martini Ford Motor Company Global Powertrain Manufacturing Engineering Systems Reliability and Maintainability Supervisor 

Reliability Centered Maintenance • What is Reliability Centered Maintenance? • RCM History • RCM Specifications • Maintenance Strategies • RCM Steps • Next Steps-Opportunities

Reliability Centered Maintenance • RCM is a process to determine what must be done to ensure that a physical asset continues to do what its users want it to do • RCM focuses on reducing failure consequences,  – via a Risk Management Tool  – without compromising safety or operating capability  – Standard maintenance decision logic

RCM History • RCM was started in the airline industry because traditional methods based on preventing asset deterioration rather than minimizing failure consequences were too costly and not effective (1965) •  As the RCM process was adopted by other industries, it was streamlined and simplified • The foundation for modern RCM was published in the book Reliability-Centered Maintenance, Second Edition by John Moubray (1992) • SAE JA1011 & JA1012 standardized latest RCM (1998)

Different RCM Specifications SAE J1011

Society of Automotive Engineers, Evaluation Criteria for RCM Processes

SAE J1012

Society of Automotive Engineers, Guide to the RCM Standard 

 A066-579

Nowlan and Heap, Reliability Centered Maintenance

MIL-STD-2173

Reliability Centered Maintenance Requirements for Naval Aircraft, Weapons Systems, and Support Equipment 

NAVAIR 00-25-403 Naval Air Systems Command, Guideline for Naval  Aviation Reliability Centered Maintenance Process Moubray, John, Reliability Centered Maintenance 2   ATA MSG-3

Air Transport Association of America,Operator Manufacturer Scheduled Maintenance Development 

The Maintenance Sweet Spot

Economically Optimal PM level

Net Cost

Functional Failure Costs

PM Costs Number of PMs

While there is a theoretical optimal PM level that minimizes cost, in the “real world” there are both too many and too few PMs being performed in a plant. 6

Maintenance Strategies

Maintenance

Predictive/ Condition Monitoring

Looks for unsatisfactory conditions

Preventative/ Restorative

Minimizes unsatisfactory conditions

Failure Finding

Redesign

Run to Failure

Looks for already failed conditions

Eliminates unsatisfactory conditions

 An acceptable strategy

7

Reliability Centered Maintenance

•

The RCM Process consists of 4 Major Steps 1. Set Asset Priorities 2. Identify asset functions, performance standards, and functional failures, failure mode and failure effects & consequences 3. Failure mode risk analysis 4. Failure management policies

Step 1. Set Asset Priorities • First Application Assets (new machines) •  Assets with historically high maintenance •  Assets based on operational criticality (i.e. single path) •  Assets with high multiples

Step 2. Component Washer Pump Example

Sub-systems/ Components

1) Performance Standards - What are the 2) Sub-system Functional Failure functions and associated desired standards of In what ways can it fail to fulfill its performance of the asset in its present functions (functional failures)? operating context (functions)?

Top section of high pressure pump

Provide washer fluid at 3,500 psi pressure Pressure and flow out of and xx GPM flow for each application specification limits

Step 2. Component Washer Pump Example

3) Cause - What causes 4) Effect - What happens each functional failure when each failure occurs (failure modes)? (failure effects) ?

5) Consequence - In what way does each failure matter (failure consequences) ?

Risk Assessment (R/Y/G)

Labyrinth seal wear (life limited component)

8 hrs of Downtime, $ repair costs

 Yellow

Machine alarms and stops

Step 3. Risk Management Decision         1 Score

Likelihood

1

> 1 i n a n h our  

        2

2

1 ina shift

        3

3

1 in a day

4

1 in a week

5

1 in a m onth

6

1 in3 months

7

1 in6 months

8

1 in a year  

9

1 in2 years

10

<1in 5 years

        d        4       o       o       5         h         i         l       e        6         k         i         L       7         8         9         0         1

7

6

5 4 3 2 Consequence

Score

Asset Downtime

This filter speeds analysis:

1

more than 8 hours

•Eliminates unnecessary analysis •Helps team make faster choices

2

4 to 8 hours

3

1 to 4 hours

4

30 min to 1 hour  

5

10 - 30 min

6

< 10 min

7

1 cycle

1

Component Washer High Pressure Pump • Failure Management Policy  – Condition Monitoring utilized • Output pressure monitoring

Next Steps - Opportunities What steps can Community Colleges take to prepare students in the field of Maintenance? 1. Create a research assignment for students related to the maintenance field 2. Teach students how to become proficient in the latest Predictive Technologies 3. Basic Data Analysis for Predictive Technologies 4. Basic and Advanced Troubleshooting Methods 5. Scheduling and resource optimization for Maintenance 6. Inventory and Storeroom Management