Reliability Centred Maintenance - a reliability improvement technique

Duration - 3/5 days

Introduction

RCM has been used extensively in the process sector since the early 1990s. RCM is a very structured approach for optimising maintenance strategies, but it is also a reliability improvement technique.
Companies who have adopted this methodology have shown significant improvements, especially when applied to critical or problem systems or equipment.
This 3-5 day workshop introduces a structured Maintenance Strategy Review (MSR) process that can be applied to new or existing assets. RCM methodology forms part of that review. Classical RCM can be applied across the whole plant but is typically used on the high critical or a bad actor system/equipment. Other less rigorous approaches are applied to lower critical items.
This workshop covers main RCM phases - Understanding, Functional Analysis, FMEA, Failure Characteristic Analysis, and Strategy Selection. Finally, we deal with the outputs and how to implement the results in the CMMS.

Key Benefits of Attending

Learn cost effective approaches to implement a Maintenance Strategy Reviews
Understand the value of reliability techniques
Understand the effects of different strategies
Learn the RCM process and how to implement
Understand the advantages and disadvantages of RCM's different approaches
Learn how user friendly software can support your RCM studies

Contents

Topic 1: Terms and Definitions
Common terms used in Reliability, RCM, and maintenance strategy reviews

Topic 2: Introduction to MSR
Maintenance Strategy Review Process (MSR), background to RCM, FMEA, FMECA, Reverse RCM, Generic FMEAs & Strategies
When to apply RCM
Advantages of applying RCM in the design phase

Topic 3: Overview Criticality Analysis
How to conduct a criticality analysis, different approaches, what to do with the results
Criticality versus Prioritisation

Topic 4: Basic Reliability to Support RCM
Bath tub curve, Weibull analysis
Charts & plots
Discussion on MTBF
Considering total costs, safe life, cost effective life, B-10 life

Topic 5: Planning & Preparation Phase
Building the team, roles and responsibilities
Training
Preparation decisions

Topic 6: Understand the Study System or Equipment
Data & document collection
Block diagrams to aid understanding
Selecting boundaries

Topic 7: Function Analysis
Primary & secondary functions
Functional failures
Specifying performance criteria

Topic 8: Failure Modes & Effects Analysis
Writing good failure modes
Local and system effects
Categorising failure consequences, e.g. hidden, evident

Topic 9 Failure Characteristics Analysis
Degradation parameters
P-F Intervals
Repair parameters
Estimating reliability

Topic 10: Strategy & Task Selection
Different maintenance strategies
Selecting strategies using logic diagrams
Task definition

Topic 11: Protective systems
Dealing with hidden failures
Selecting function test intervals

Topic 12: Implementation
Task packaging
Migrating to the CMMS

Topic 13: Continuous Improvement
When to conduct future reviews

Topic 14: Alternative Strategy Approaches
Reverse RCM, FMEA

Topic 15: RCM Software
Overview of software solution

Course Review and Delegates' Actions Plans

Training Methodology

PowerPoint slides. Delegates will learn by active participation during the workshop and through exercises, case studies, an off the shelf software application will be shown

Who Should Attend

Maintenance Managers, Engineers, Analysts
CMMS Key Users
Warehouse Managers & Supervisors
Project Engineers
Spares & Inventory Personnel