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Reliability Centered Maintenance:

General Introduction
RCM
• A pre-eminent
pre eminent method for establishing a
scheduled maintenance program.
• Demonstrated to be highly effective in many
industries
• SAE Standard JA1011 on RCM evaluation
criteria
What Is RCM?
• A logical, technical process that determines which
maintenance tasks will ensure a reliable system, under
specified operating conditions.
• It
I ddelves
l into
i how
h theh system works,
k whath can go wrong
in the system, and how to deal with these possible
failures.
• The goal is to make the system as reliable as it was
designed to be.
• It is critical to understand the operating conditions:
location, atmosphere, humidity, speed, acceleration, etc.
Why Use RCM?
• It works
works. Proven in its use in many industries
industries.
• Airline industry; Military equipment; Mining
industry; Process industry;
• The main reasons: Knows the system, Know
what mayy ggo wrong,g, Know the consequences
q of
the possible failures, Selects suitable strategies to
deal with them, Utilize condition monitoring,
time-based PM, usage-based PM, run to failure,
etc.
Who Should Use RCM?
• Any plant,
plant fleet,
fleet or building in which
productivity is essential.
• For example, demand is high (oil & gas
industries); tight delivery schedule
(manufacturing); availability has to be high;
possibly being sued.

Total time - Failure downtime MTBF


Availability= =
Total Time MTBF+MTTR
The RCM Process
• Identify the system to be analyzed
• Determine its functions
• What are possible failures of the functions?
• What could cause these failures?
• What are the consequences of the failures?
• Select appropriate maintenance tactics
• D
Document t th
the maintenance
i t program andd refine
fi as
needed
What System to Study?
• Personnel safety
• Environmental compliance
• Production capacity
• Production quality
• Production cost (including maintenance cost)
• Public image
What May Go Wrong?
• What are the functions? What is normal?
• Possible failures: high, low, on, off, open, closed,
breached, drifting, stuck, etc.
• Failure mode? Failure cause? Hydraulic cylinder
stuck: Poor lubrication,, Leaking,
g, Surface
corrosion, etc.
q
• What are the consequences?
• Hidden failure or self-revealing failures?
Detectable? Condition monitoring.
• FMECA
Task Grouping
• For each plant,
plant there are numerous systems
systems.
• For each system, there are numerous devices.
• For each device,
device there are several functions.
functions
• For each function, there may be several failures.
• For each failure,
failure there may be many failure
modes with varying effects and consequences.
• For each failure mode,
mode there is a task.
task

• How to group tasks? Monitoring


Monitoring, PM
PM, etc
etc.
RCM Implementation
• Select a team of practitioners
• Train them in RCM
• Teach other stakeholders in RCM
• Select a pilot project for RCM
• Roll out RCM to other facilities
The RCM Team
• Multidisciplinary
• Equipment, Operations, Reliability, Design, etc
• Members: Maintainer,
Maintainer Operator,
Operator Operations
Manager, Maintenance Manager, Engineering
Designer,
g , Reliabilityy Engineer
g
• Training, Communication, Top Management
Commitment
Cost of RCM
• RCM implementation can be costly.
costly If well done,
done
the benefits are much greater.
• Average 10 person
person-years
years for staff time alone
(easily $700,000 in total). Training time,
Consulting fees, Reliability and maintenance
software packages, etc.
Reasons for RCM
Implementation Failures
• Lack of top management support
• Lack of vision of what RCM can do
• No clearly stated reason for doing RCM
• Conflict among stakeholders
• Giving up too early
• Errors in the pprocess of doing
g FMECA,, reliability
y
analysis, etc.
• Lack of information on equipment
• Others
Reference
• J D Campbell and AKS Jardine, Maintenance
Excellence: Optimizing Equipment Life-Cycle
D ii
Decisions, Marcel
M l Dekker,
D kk NewN Y York,
k 2001