RCM: Establishing Preventive Maintenance

Requirements
13 – Nov - 2012
Presented to:
DoD Maintenance Symposium
Grand Rapids, MI

Presented by:
Sean Olin
RCM National Lead, AIR-6.7.1.2

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

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 Topics

• Reliability Centered Maintenance

– Definition
– Precepts and Steps
• RCM and CBM
• Integration with Supportability and CBM+

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 Reliability Centered Maintenance

“RCM is used to determine what failure

management strategies should be applied
to ensure a system achieves the desired
levels of safety, reliability, environmental
soundness, and operational readiness in
the most cost-effective manner. ”
-- DoDM 4151.22-M

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 RCM
RCM develops logical decisions based on the following
precepts:
• The objective of maintenance is to preserve an item’s
function(s).
• RCM seeks to manage the consequences of failure – not to
prevent all failures.
• RCM is driven first by safety. When safety is not an issue,
maintenance must be justified on the ability to complete the
mission and finally, on economic grounds.
• RCM acknowledges that at best, maintenance can only
sustain the system to its inherent level of reliability within the
operating context.
• RCM uses design, operations, maintenance, logistics, and
cost data, to improve operating capability, design and
maintenance.
• RCM is a continuous process that requires sustainment
throughout the life cycle.

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 RCM
The RCM process includes identifying the
following items in sequence.
The desired capability of the system, how well it performs, and
1. Functions under what circumstances

The failed state of the system (e.g., the system falls outside the
2. Functional Failures
desired performance parameters)

3. Failure Modes The specific condition causing a functional failure

Description of what happens when each failure mode occurs,

4. Failure Effects detailed enough to correctly evaluate the consequences of
each
The description of how the loss of function matters (e.g. safety,
5. Failure Consequences environmental, mission, or economics

6. Maintenance Tasks The description of applicable and effective tasks, if any,

and Intervals performed to predict or prevent failures
Including, but not limited to, run-to-failure, engineering
7. Other Logical Actions redesigns, and changes/additions to operating procedures or
technical manuals
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 RCM and CBM
• RCM and Condition Based Maintenance (CBM)

• Working Definition for CBM: A course of action, for a

failure mode, developed through RCM that allows user
to:
– manage operation based on knowledge of condition
– balance risk and consequences
– monitor or track direct or indirect indicators of assets reliability
and Remaining Useful Life (RUL) or Consumed Life

• Recommended practices in work (SAE G-11)

• Bottom Line: Allows item to remain in service longer, and

with prognostics, to determine options for course of
action.
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 RCM and CBM

Functional
Failure Probability

Failure
Potential Failure
(Detectable condition
and unacceptable risk)

CBM Trigger
(Detectable condition
and acceptable risk)

Time sufficient to
plan for repair and
obtain resources

I = Traditional I I I I I I I I
Inspection
Interval
TIME
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 RCM Integration in Supportability
Design Maintenance Maintenance Maintenance
Interface Planning Scheduling Execution

OperationalDemand
Operational Demand
Planning
Planning
System Description & Operation (i.e. CONOPs , Op. Architecture, PSE LEMS
 Drawings (i.e. CONOPs , Op. Architecture, Training
 Functional Block Diagram WSPD, TYCOM
WSPD, TYCOM Plans)Plans) Tech Data
Manpower
SE
Spares
PHS&T
D/I FMECA LORA Facilities
Tools, etc
Failure Modes L&Sim Inputs
 Use study Existing Repair Cap
 BCS – CA “Default” Data
 Functional RQMTS
On-Aircraft Maint.
 Standardization/
O, I, D
interoperability
 AoA Maint.
 Trade Studies
RCM MTA Data
Scheduled Maintenance Tasks
 Fly to Fail Tools/SE
O-level
 Hard time TTR Off-Aircraft Maint.
I-level
 Failure Finding Skills/Rate
D-level
 Lube – Service Facility Requirements
 Condition monitoring Manpower
• PHM/CBM+ Consumables Unscheduled Maintenance Tasks
• Inspect & Repair Repairables
• Conditional Task PHS&T
 Other (redesign, ECP) O-level
Computer Resources I-level
 Age Exploration HAZMAT/Environmental D-level
Task level
feedback

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 RCM and CBM+
• “RCM provides the evidence of need for other CBM+
processes and technologies, such as health monitoring
or prognostics. RCM provides an understanding of the
applicability and effectiveness of proposed CBM+
technologies as well as an analysis of alternatives.”
-- DoDM 4151.22-M

• Tenets:
– RCM outcomes, whether they be PM or “other logical action”,
may be considered for CBM
– Consider implementation cost
– Consider reliability of CBM solution
– Data feedback is critical to all supportability elements