CECOS University Of IT and Emerging

Sciences Peshawar
Mechanical Department

TOPIC:RELIABILITY,CENTRED MAINTENANCE
RELIABILITY

By:kifayat ullah
Email:kifayatullah318@gmail.com

Reliability

Reliability is a measure of the probability that an item will perform its

intended function for a specified interval under stated conditions. There are
two commonly used measures of reliability:
* Mean Time Between Failure (MTBF), which is defined as: total time in
service / number of failures
* Failure Rate (), which is defined as: number of failures / total time in
service.

Reliability centered maintenance:

Definition: Reliability centered maintenance (RCM) is a corporate-level
maintenance strategy that is implemented to optimize the maintenance
program of a company or facility. The final result of an RCM program is the
implementation of a specific maintenance strategy on each of the assets of
the facility. The maintenance strategies are optimized so that the
productivity of the plant is maintained using cost-effective maintenance
techniques.
There are four principles that are critical for an reliability centered
maintenance program.
1.

The primary objective is to preserve system function.

2.

Identify failure modes that can affect the system function.

3.

Prioritize the failure modes.

4.

Select applicable and effective tasks to control the failure modes.

RCM History:
1965: Studies show scheduled overhaul of complex equipment has little or
no effect on in-service reliability
1970: RCM had its beginning in the commercial airline sector in 1970's. At
that time, the commercial airline industry was experiencing high number of

crashes in the take-offs which majority of them was related to equipment

failures
After applying the RCM method, it proved to be highly successful; in
commercial airlines it reduced crashes from 60 per million take-offs to only 2
per million and more important than that reduced the equipment related
crashes from

40 per

million to only

0.3 per

million take-

offs.

Types of RCM:
There are different ways to conduct and implement an RCM program;

Classical/Rigorous
Classical or rigorous RCM provides the most knowledge and data concerning system
functions, failure modes, and maintenance actions addressing functional failures of any of
the RCM approaches.

Intuitive/Streamlined/Abbreviated
The intuitive approach identifies and implements the obvious,
usually condition-based, tasks with minimal analysis. In addition, it culls or
eliminates low value maintenance tasks based on historical data and
Maintenance and Operations (M&O) personnel input.

The Principles of RCM:

RCM is Function Oriented.

RCM is System Focused

RCM is Reliability-Centered

RCM Acknowledges Design Limitations

RCM is Driven by Safety, Security, and Economics

RCM Defines Failure as "Any Unsatisfactory Condition

RCM Uses a Logic Tree to Screen Maintenance Tasks.

RCM Tasks Must Be Applicable

RCM Tasks Must Be Effective

RCM Acknowledges Three Types of Maintenance Tasks :

Time directed (PM)

Condition directed (CM)

Failure finding (Proactive Maintenance)

RCM is a Living System

The RCM Process Basic Steps:

RCM is not a stand-alone process, it must be an integral part of the
Operations and Maintenance program.the following step can be define as follows.
Preparation

The preparatory phase has a number of steps which basically involve the
selection of the systems to be analysed, gathering the necessary data for the
analysis. In addition the ground rules or criteria to be used in the selection
and analysis process must be established. The stages can be summarised as
follows:

System Selection.

Definition of the system boundaries.

Acquisition of Documentation and Materials.

Interviews with Plant Personnel.

Analysis

Once the systems have been selected for analysis and the preparations have
been completed the analysis can commence. Experience in the analysis
process is important for effective decision-making. Such experience may

exist in the utility or it may be bought in from specialist service providers in

this area. The analysis involves the following stages.

Identification of System Functions

System Functional failure analysis

Equipment identification

Reliability and Performance Data collection

Identification of failure modes

Identification of failure effects

Determination of Component Criticality

Task Selection

The task selection process uses various forms of logical

decision making to arrive at conclusions in a systematic manner. The
outcomes can include:

Preventive maintenance

Condition monitoring

Inspection and functional testing

Run to Failure

Task Comparison

When the task selection has been completed and reviewed, the
recommendations arising from the task selection process will be compared
against the current maintenance practices. The purpose of this comparison is
to identify the changes needed to the maintenance programme and the
impact on resources and other commitments.
Task Comparison Review

The outputs of the analysis will result in a change to the maintenance

programme. It is important that such changes are consistent with the
maintenance philosophy of the plant and with regulatory and social
obligations. For this reason it is important that the process and its outcomes
be subjected to a final review.
Records

RCM should form part of a living programme. The outcomes of the analysis
process and the implementation of the recommendations will have an impact
on the effectiveness of the operations and maintenance programmes. It is
important therefore, that all decisions, the basis for them and those involved
in making them are effectively recorded, so that the information is available
to those carrying out subsequent reviews of the maintenance strategy.

ADVANTAGES

Can be the most efficient maintenance program.

Lowers costs by eliminating unnecessary equipment maintenance or

system overhauls.

Minimizes the frequency of overhauls.

Reduces probability of sudden equipment failures.

Focuses maintenance activities on critical system components.

Increases component reliability.

Incorporates root cause analysis.

DISADVANTAGES

Can have significant startup costs associated with staff training and
equipment needs

Savings potential is not readily seen by management.

RCM is not cheap; it imposes many accomplishing costs to system, for

example training costs and costs of employing some new experts for
replacement with those who entered in the program and have not
enough time to fulfill their responsibilities as before.

Dealing with hidden failures causes challenges for many analysts (and
then others) not familiar with the concept

Reliability-Centered Maintenance Methodology

Reliability-centered maintenance (RCM) is the optimum mix of reactive, time or
interval-based, condition-based, and proactive maintenance practices. These
principal maintenance strategies, rather than being applied independently, are
integrated to take advantage of their respective strengths in order to maximize
facility and equipment reliability while minimizing life-cycle costs.
Total productive maintenance (TPM), total maintenance assurance, preventive
maintenance, relia-bilitycentered maintenance (RCM), and many other innovative
approaches to maintenance problems all aim at enhancing the effectiveness of
machines to ultimately improve productivity

Reliability-Centered Maintenance Components

The components of RCM program are shown in Figure 1. This figure showing that RCM program consists of
(reactive maintenance, preventive maintenance, condition based maintenance, and proactive maintenance)
and its patterns.