Reliability Centered Maintenance – Reengineered

Practical Optimization of the RCM Process with RCM-R®

Jesus R. Sifonte, James V. Reyes-Picknell

• Publisher: Productivity Press
• Year: 2017
• ISBN:
  9781351799065
• Edition: 1
• Topic: Business
• Subtopic: Operazioni
• Index: Business

Reliability Centered Maintenance – Reengineered: Practical Optimization of the RCM Process with RCM-R® provides an optimized approach to a well-established and highly successful method used for determining failure management policies for physical assets. It makes the original method that was developed to enhance flight safety far more useful in a broad range of industries where asset criticality ranges from high to low. RCM-R® is focused on the science of failures and what must be done to enable long-term sustainably reliable operations. If used correctly, RCM-R® is the first step in delivering fewer breakdowns, more productive capacity, lower costs, safer operations and improved environmental performance. Maintenance has a huge impact on most businesses whether its presence is felt or not. RCM-R® ensures that the right work is done to guarantee there are as few nasty surprises as possible that can harm the business in any way.

RCM-R® was developed to leverage on RCM's original success at delivering that effectiveness while addressing the concerns of the industrial market. RCM-R® addresses the RCM method and shortfalls in its application -- It modifies the method to consider asset and even failure mode criticality so that rigor is applied only where it is truly needed. It removes (within reason) the sources of concern about RCM being overly rigorous and too labor intensive without compromising on its ability to deliver a tailored failure management program for physical assets sensitive to their operational context and application. RCM-R® also provides its practitioners with standard based guidance for determining meaningful failure modes and causes facilitating their analysis for optimum outcome.

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• Includes extensive review of the well proven RCM method and what is needed to make it successful in the industrial environment

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• Links important elements of the RCM method with relevant International Standards for risk management and failure management

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• Enhances RCM with increased emphasis on statistical analysis, bringing it squarely into the realm of Evidence Based Asset Management

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• Includes extensive, experience based advice on implementing and sustaining RCM based failure management programs

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Contents

Foreword

Introduction

Chapter 1 Asset Management

References

Chapter 2 The History of RCM and Its Relevance in Today’s Industry

RCM Development

References

Chapter 3 The RCM-R® Process

The Sae JA1011 Rcm Standard

Operational Context and Functions

Functional Failures

Failure Modes

Failure Effects

Failure Consequences

Maintenance Strategies Selection

Reliability Centered Maintenance-Reengineered (RCM-R®)

RCM-R® Project

System Description

Reliability, Availability, and Maintainability (RAM) Analysis

Current Situation Explained

Failure Data Analysis at a Glance

Introduction to Weibull Distribution and Analysis

Optimum Replacement Time Analysis

Detailed Failure Data Analysis Using the Weibull Distribution

Conclusions

The RCM-R® Process Diagram

References

Chapter 4 RCM-R® Pre-work

Ensuring Asset Data Integrity

Rcm-R® Data

Asset Data Registers

Work Order Data

Asset Criticality Analysis

Chapter Summary

References

Chapter 5 Functions and Failures

The Operating Context

Performance Levels

Functional Analysis

Primary Functions

Secondary Functions

Protection

Efficiency and Economy

Appearance

Control, Containment, and Comfort

Health and Safety

Environmental Integrity

Structural Integrity and Superfluous Functions

Hidden Functions

Functional Block Diagrams

Failure Types and Classes

Types of Failures: Functional and Potential Failures

Classification of Functional Failures

Chapter Summary

Chapter 6 Failure Symptoms and Causes

Brainstorming

Failure modes

Failure mode types

Root causes of failure modes

How much detail?

Chapter summary

Chapter 7 Quantifying Failure Impacts

Guide Questions for Describing Failure Effects

How is The Failure Detected?

How is the Safety of the People around the Failed Asset Affected?

How are Environmental Goals Impacted?

How is Production or Operations Affected by the Failure?

What Kind of Physical Damage is Caused by the Failure? How Costly is the Failure in Terms of Maintenance and Repair?

Is There any Secondary Damage? What Must be Done to Restore Operations? How Long Would it Take?

Documenting Failure Effects Statements in the RCM-R® Worksheet

ISO Standard-Based Failure Effects Risk Analysis

RCM-R® Failure Effects Risk Assessment Matrix

Chapter Summary

References

Chapter 8 Overview of Maintenance Strategies

Overview of Strategies for Managing Failure Consequences

Technically Feasible and Worth Doing

Preventive Maintenance

Predictive Maintenance (PDM)

Detective Maintenance (Failure Finding) (DM)

Running To Failure (RTF)

Nonrecurring Actions (One-Time Changes)

Design Change Objectives

Timing

Describing One-Time Changes

Chapter Summary

Chapter 9 Condition-Based Maintenance Techniques

Vibration Analysis

Jesús R. Sifonte

Vibration Parameters and Units

Vibration Analyses

Machine Condition Diagnosis with Vibration Analyses

Vibration Analysis Diagnostic Example

Infrared Thermography

Wayne Ruddock

Introduction and History

Basic Infrared Theory

Applications of Infrared Thermography in Predictive Maintenance (PDM)

Electrical Inspections

Mechanical Inspections

Process Inspections

Facility Inspections

Precision Lubrication and Oil Analysis

Mark Barnes

Identifying Lubrication-Related Failure Modes

Lack of Lubrication

Too Much Lubricant (Overlubrication)

Wrong Lubricant Selected

Wrong Lubricant Added

Lubricant Contaminated with Moisture

Lubricant Contaminated with Particles

Lubricant Degraded

Lubricant Too Hot/Cold

Additives Depleted

Lubricant Contains Foam/Air Entrainment

Oil Analysis as a Predictive Tool of Other Problems

Sampling Frequency

Sampling Location

Oil Analysis Test Slate

Ultrasound

Allan Rienstra

Sound Principles

The Basics

Frequency (F)

Period (T)

Measuring Sound

Velocity of Sound and Acoustic Impedance

Sound Propagation through Air

How Ultrasound Detectors Work

How Ultrasound Is Collected

Airborne Sensors

Contact Sensors

Why Ultrasound Is an Effective Technology

Applications

Compressed Air Leak Management

Condition Monitoring

Slow-Speed Bearings

Acoustic Condition-Based Lubrication

Electrical Applications

Steam System Inspections

Pump Cavitation

Reciprocating Compressors and Valves

Heat Exchanger and Condenser Leaks

Ultrasound for Reliability

Nondestructive Testing

Jeff Smith

Conventional NDT Methods

Advanced NDT Methods

Conclusion

References

Chapter 10 Selecting Strategies for Managing Failure Consequences

Categories of Failure Consequences

Failure Consequence Management Policies’ Nomenclature and Typical Decision Diagrams

Hidden Failures Consequence Management Tasks

Safety and/or Environmental Consequence Management Tasks

Production Consequence Management Tasks

Maintenance Consequence Management Tasks

RCM-R® Failure Consequence Management Decision Diagram

Developing Meaningful Maintenance Tasks

Chapter Summary

Chapter 11 Fine-Tuning RCM Analysis

The Need for Better Data

Reliability, Availability, and Maintainability (RAM) Analysis

Failure Data Analysis

Weibull Analysis

Creating and Interpreting Weibull Data Plots

Periodic Tasks Frequency

Chapter Summary

References

Chapter 12 Implementing RCM-R

The Analysis Team

The Facilitator

Training and Competency

Preparation

Estimating the Effort

Conducting the Analysis

Implementing the Outcomes

Implementing C and T Tasks

Implementing D Tasks

F Outcomes

R Decisions

Monitoring and Continuous Improvement

Monitoring and Improvement Tools

Governance for Sustainability

Chapter 13 Leveraging RCM-R®

Concept

Integrated and Iterative?

Why Bother?

Industrial Life Cycle Support

Condition Monitoring Support

Time-Based Task Support

Detective Maintenance Support

Run to Failure (F Tasks)

Providing Support

Documentation and Records

Skills and Capabilities

Facilities

Spares

Neil Montgomery

Chapter Summary

Appendix A

Appendix B

Epilogue

Index

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Foreword

This book by James Reyes-Picknell and Jesús R. Sifonte is a welcome addition to the literature on reliability centered maintenance (RCM). Over the last decade, the workplace has changed, and RCM has evolved to meet the needs of today’s companies. Although papers have appeared charting this evolution, the book represents an opportunity to reflect on and consolidate the findings. This is not a backward-looking volume, however. Far from it. Rather, its cutting-edge analysis points to the continued relevance of RCM well into the future.

Reyes-Picknell and Sifonte are extremely well positioned to tackle the project—with strong backgrounds in both theory and practice. They begin the book with an explanation of the value of RCM in the current context. Then, in Chapter 3, they hint at the future with an introduction of the changes involved in their formulation of RCM-R® (reliability centered maintenance-reengineered). Of course, RCM-R® is not simply a theory, and the following chapters go on to explain its practical application—supplemented by numerous very helpful examples, along with figures highlighting the main points.

To put it simply, RCM-R® takes RCM a step further by making it more evidence based where data are available. In general, RCM-R® requires operational, technical, reliability, maintenance-related, failure, material, financial, safety, and environmental data to be analyzed for decision-making purposes. The effort to take RCM a step further is, in fact, an overriding theme of the book. A particularly valuable example is Chapter 9 on condition-based maintenance techniques, where the authors, along with several colleagues, contribute detailed insights into the condition monitoring technologies of vibration analysis (Jesús Sifonte), infrared thermography (Wayne Ruddock), lubrication and oil analysis (Mark Barnes), ultrasound (Allan Rienstra), and nondestructive testing (Jeff Smith). In Chapter 12, they extend RCM into the provisioning of spare parts, including a section on slow-moving capital spares written by Neil Montgomery.

Andrew K. S. Jardine
University of Toronto

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Introduction

WHY RCM-R®?

RCM was successfully developed during the 1970s while the aviation industry was facing important challenges. High maintenance costs, frequent undesirable component failures, and the safe increase in passenger capacity of aircraft designed to meet Federal Aviation Agency requirements were some of the struggles the aviation industry overcame with the development of its novel process to determine failure consequence management policies for aircraft nonstructural components. Later on, the so-called reliability centered maintenance process was introduced with success in the mining and nuclear industries. The development of an international asset management standard (ISO 55000) in 2014 ...