Maximizing Reliability- How RCM Goes Beyond Maintenance

Abstract

The misconception that RCM (Reliability Centered Maintenance) is just a type of maintenance is discussed in this article. In reality, RCM is a process or methodology that aids in choosing the most effective and efficient combination of maintenance strategies to prevent failures in crucial areas or systems. RCM works effectively in fields where failure has serious repercussions. The article also describes the procedures for putting an RCM program into effect, including establishing the project's goals and scope, ranking project goals, evaluating priorities, deciding on training needs, executing the plan, and maintaining the RCM program. The article underlines that RCM is not appropriate for all systems and equipment while also providing examples of effective applications of RCM approaches.

Introduction

The technique or approach of reliability-centered maintenance (RCM), which helps identify the best, most efficient, and most effective combination of maintenance tactics to prevent failure modes in critical systems, is discussed in the article. The article focuses on RCM's successful implementation & and sustenance, its potential to reduce maintenance costs, and deflates the industry myth that it is just another form of maintenance. The article also offers a structure for starting an RCM program that needs a clear understanding of the project's scope, prioritizing that scope, evaluating priorities, identifying the staffing and training needs, putting the plan into action, and maintaining the RCM program.

RCM- A Process-Oriented Approach to Optimize Maintenance Strategies and Prevent Failure in Critical Systems

There is a lot of misconception in the industry about RCM. Most people believe that RCM (Reliability Centered Maintenance) is a type of maintenance, but it is not. RCM is a process or methodology, that assists in determining the most optimal, effective & and efficient combination of maintenance strategies to avoid failure modes in critical systems or in critical areas of facilities. So, the objective and execution of RCM differs totally from traditional maintenance types, like preventive maintenance or reactive maintenance. Three engineers, Tom Matteson, Howard Heap, and Stanley Nowlan, pioneered Reliability Centered Maintenance. They developed a study for United Airlines aircraft maintenance and reliability requirements, which was later funded by the United States Department of Defense.

So, we can say, RCM is always used where there are “high consequences” for failure. A flaw in a pharmaceutical drug, for example, can affect thousands of people who take it, potentially causing harm, illness, or even death. This is why pharmaceutical companies use RCM. However, its applicability is not limited to large organizations or capital-intensive industries and can be implemented in any facility, regardless of its size or industry. However, RCM implementation is not a simple task. It is a complicated and complex strategy that directs your operational processes toward maximum uptime. Condition monitoring, FMEA (Failure Modes and Effects Analysis), and designing for reliability all help teams predict, diagnose, and work toward devising a successful RCM methodology for a critical system or critical area of the facility.

Example of successful implementation of RCM method:

Did you know that since it started using RCM at its Marshall Flight Center facilities, NASA has saved more than $300,000 in maintenance costs? With the use of NASA's RCM strategy, which is mostly used for pressurized systems, the organization has decreased energy use, enhance worker safety, reduce environmental impact, and prolong the life of aged equipment.

RCM has also allowed The National Ignition Facility to save $2 million in maintenance expenses. It has eliminated normal maintenance tasks that were ineffective thanks to the RCM strategy. Instead, it emphasized spotting possible issues and how to deal with them successfully. 

Building a Successful RCM Program: A Step-by-Step Guide to Implementation and Sustainability

Not all systems and equipment need RCM methodology, as stated above it is applicable to “systems, where there are “high consequences” for failure, live in aviation, nuclear power plants, hospitals, etc.

The process of launching an RCM program varies depending on the organization, site, and system type—one RCM program structure does not fit all organizations.

The framework provided below provides the main components of a functional program; the program weighting and level of activity within any one element will be determined at the local level. These steps are a compilation of approaches discovered through a variety of sources (FEMP 2010, DoD 2011, NASA 2008, and SAE 1999) and are provided as an outline and jumping-off point.

Step 1: Determine the scope of the project. The goal of this step is to define the RCM program's project scope and objectives, specifically:

• Which facilities or systems will be considered, if any?
• What are the defined goals? (e.g., reliability, efficiency, safety, and resilience).

Step 2: Prioritize the scope of the project. This step aids in the organization of potential RCM activities based on their importance or criticality to the operation, process, or mission. Table 1 depicts a system weighting for RCM development (PNNL 2010). Systems with weightings of one, two, or three are typically prioritized as having the greatest RCM potential. The goal is to assign risk or criticality levels based on the consequences of failure.

Step 3: Priorities must be assessed. We determine the maintenance approach for each relevant system or component based on system prioritization and the RCM analysis methods presented above. The figure-1 below (adapted from NASA 2008) depicts a logic tree that can be used to guide system- and component-level RCM decision approaches.

Step 4: Staffing and training requirements. The transition to a functional RCM program will necessitate extensive staff training. Training should begin with a focus on RCM principles and then shift to a focus on the relevant RCM processes and technologies.

Step 5: Put your plan into action. Given the potential complexity of an RCM program, the implementation should begin gradually, possibly with a pilot program. Consider starting with a target system that has been difficult to maintain but has definable success indicators. Systems that support critical functions and are subject to downtime may also be suitable candidates. A well-defined way to measure benefits is to select a system with performance indicators (KPIs) that will be compared against benchmarks (industry standards or internally developed).

Step 6: Sustaining the RCM Program.

To measure and report progress, RCM metrics can be divided into three reporting categories:

• Business metrics,
• Program management metrics
• and, technical metrics.

The RCM program's costs and advantages for the resource supplier, end users, and clients are shown via business reporting. Technical metrics define the functional elements of the systems and equipment, whereas program metrics evaluate the development and feasibility of the program. A healthy RCM program may be maintained and will produce a program that is cost-justified, flexible, and resilient if program data and benefits are reliably captured, analyzed, and reported.

Conclusion

Businesses employ the (RCM) technique to determine the ideal mix of maintenance tactics to ward off failure modes in crucial systems. In sectors where failure repercussions are significant, including aviation, nuclear power plants, and healthcare, RCM is crucial. A sophisticated strategy that includes condition monitoring, FMEA, and designing for reliability is the implementation of an RCM program. Depending on the business, location, and system type, different steps are involved in starting an RCM program. Yet, companies can gain from increased dependability, efficiency, safety, and resilience by adhering to a framework that establishes the project scope, evaluates priorities, establishes personnel and training needs, implements the plan, and maintains the RCM program.