rcm ala maximo

8/11/2019 RCM Ala Maximo

1/10

Reliability Centered Maintenance (RCM) and MAXIMO

An MRO Software White PaperJanuary 2004

Version 3.0

Timothy H. Trout, C.P.M.M.Johan Arts

MRO Software100 Crosby Drive

Bedford, MA 01730Tel: +1 (800) 244-3346Fax: +1 (781) 280-2202

www.mro.com
http://www.mro.com/http://www.mro.com/


2/10

Reliability Centered Maintenance and MAXIMO

1. Introduction...........................................................................................................3

2. What is Reliability Centered Maintenance? ........................................................3

3. Why invest in RCM? .............................................................................................6

4. Assessing readiness for RCM...............................................................................7

5. Implementing RCM using MAXIMO...................................................................8

6. Customer case .......................................................................................................9

7. Conclusions...........................................................................................................9

8. About MRO Software..........................................................................................10

9. Sources: ...............................................................................................................10

MRO Software 2003 Page 2 1/27/04


3/10


1. Introduction

The purpose of this paper is to explain what Reliability Centered Maintenance (RCM)is and how MAXIMO, the Strategic Asset Management Solution from MRO Softwarecan be used to implement an RCM based maintenance program.

The paper also includes a customer case that describes the results achieved by aMAXIMO customer that has implemented an RCM based maintenance program.

2. What is Reliability Centered Maintenance?

Reliability Centered Maintenance (RCM) is the concept of developing a maintenancescheme based on the reliability of the various components of the system or product inquestion. Implementing a preventive maintenance program using RCM can greatlyreduce the total cost of ownership of any product or system. RCM evolved during the

1950s in the aircraft industry as a result of a number of major reliability studiesconcerning complex equipment.

There have been a number of significant studies concluded that challenged thetraditional approach to scheduled maintenance programs which were based on theconcept that every item on a piece of complex equipment has a right age at whichoverhaul is necessary to ensure safety and operating reliability. Through thesereliability programs it was discovered that many types of failures could not beprevented or effectively reduced by such right age overhauls.

Two items from the findings of the 1960 FAA / Airline Industry Reliability Programstudy were:

scheduled overhauls had little effect on the overall reliability of a complex

item unless the item had a dominant failure mode; and

there were many items found for which there was no effective form ofscheduled maintenance.

Therefore, the traditional views of equipment failure as depicted by the FirstGeneration (pre World War II), and the Second Generation (post World War II) curveswere challenged and a new series of Third Generation failure curves were developedrelating to specific types of equipment.



4/10


The First Generation pattern indicates a fix it when it breaks maintenance strategy.The Second Generation pattern indicates a more engaged maintenance strategy,realizing as equipment became more complex the need for maintenance to be

involved at installation and startup was as necessary as their being involved uponfailure. While the Third Generation patterns indicate that various equipmentcomponents reflect different failure trends. Those patterns are:

Pattern Example Equipment Type

A Mechanical Equipment

B Wear Resistant Liners, Gear Boxes

C Piping, Refractory, Valves

D Hydraulics or Pneumatics

E Lubricated Ball Bearings

F Electronic Circuit Boards

Because of the Third Generation failure patterns, it became obvious that views of

equipment failure needed to change, as did what should be done to prevent failure.Imposed age limits and Time-Based Maintenance schedules often do little or nothingto improve the reliability of complex equipment. As shown in the drawing, traditionalmaintenance can actually increase failure rates by introducing infant mortality intootherwise stable systems.

Because of this there were four challenges that were recognized as requiringmaintenance to provide resolution:



5/10


How to deal effectively with each type of failure process with appropriatemaintenance tactics

How to improve maintenance productivity by moving towards a more pro-

active and planned approach

How to extend run length between scheduled shutdowns

How to ensure the active support and cooperation of people from themaintenance, material, operations and technical functions

RCM is a maintenance oriented framework to meet these challenges. Ultimately,RCM provides a structured, logical process for developing or optimizing themaintenance requirements of a physical resource in its operating context to realize itspotential reliability. The potential reliability is the level of reliability which can beachieved with an effective maintenance program. This level of reliability is a functionof the equipments design and cannot be improved without redesign.

RCM is basically a methodology to balance the resources being used with therequired inherent reliability based on the following precepts:

a failure is an unsatisfactory condition and maintenance attempts toprevent such conditions from arising;

the consequences of failure determine the priority of the maintenanceeffort;

equipment redundancy should be eliminated, where appropriate;

condition-based or predictive maintenance tactics are favored overtraditional time-based methods; and

run-to-failure is acceptable, where warranted.

RCM was developed as a strategic methodology for developing a cost effectivemaintenance plan by identifying:

what you want out of your equipment;

what your equipment can do;

the way in which it may fail to meet your requirements; and

what you can do to ensure your equipment meets your expectations in asafe and cost-effective manner.

This is achieved using a progressive logical approach based on identifying allsignificant maintainable item's:

a. Functionb. Functional Failurec. Failure Effectsd. Failure Cause

then applying a logic model to each item so as to identify tasks and maintenanceinspection intervals.

It should be noted however, this approach is severely hampered if the issues of BasicEquipment Condition, Operating Standards and Accelerated Deterioration are notaddressed first.

The development of an effective RCM program requires extensive knowledge aboutthe reliability and maintainability of the system and all of its subsequent components.Important factors include the MTTR (Mean Time To Repair), MTBF (Mean Time



6/10


Between Failure), MTBCF (Mean Time Between Causal Failure) and the failure rate(total number of failures within a given time period) of the product or system.

Figure 1 illustrates an RCM process flow:

Select

Equipment

Identify

Functions

Identify

Failure

Mechanisms

Assign

Failure

Effects

Critical

PM Task

Selection

Non-critical

Analysis

ApprovalImplement

YES

NO

Re-analysis

Start

3. Why invest in RCM?

Undesired equipment failures have a tendency to occur at the most undesired

moments (Murphys law). They tend to cause business disruptions that have an effecton the bottom line of the corporation, or its ability to comply with regulatory, or Health,Safety and Environmental (HSE) standards. They create unwanted risk for thecorporation that it will want to mitigate.

The traditional approach has been to implement a Preventive Maintenance (PM)program. Often these programs are established time-based intervals that are basedupon criteria supplied by the manufacturer. The effectiveness of the program issuspect because its been handed down over the years from engineer to engineerwith little or no review.

Effective Reliability Centered Maintenance programs lead to increasedequipment/plant availability while optimising the use of scarce resources. As a resultof this, RCM programs protect the companys ability to generate revenue while at thesame time reducing cost. RCM also has an effect on the ability to comply with safetyand environmental compliance as caused by machine failures. These benefits alldirectly impact the risk profile and the bottom line of the corporation.

Operational benefits are furthermore1:

Greater safety and environmental integrity, regulatory compliance Improved operating performance (output, product quality and customer service)

1Reliability Centered Maintenance, John Moubray, Second Edition, Industrial Press, 1997, 1992



7/10


Greater maintenance cost-effectiveness Longer useful life of expensive items A comprehensive database

Greater motivation for individuals Better teamwork

4. Assessing readiness for RCM

Implementation of a Reliability Centered Maintenance program requires a certainlevel of sophistication in the maintenance department. The figure below identifies thedifferent levels of sophistication that can be distinguished

fig. 2 RCM Readiness

Reactive Maintenance

RCM

PlannedMaintenance

Total ProductiveMaintenance

0.Reactive maintenance environmentIn this environment fire fighting is rewarded. The ratio between planned an unplannework is very much in favour of unplanned work and there is little, if any, preventivmaintenance taking

de

place. Typically the relationship between maintenance andperations is poor.

way. Work is planned to the extent possible and

rioritised according to criticality.

eady to move into the third stage of sophistication,eliability Centered Maintenance.

o1.Planned maintenanceIn this environment there is a time-based PM program in place. Perhaps somepredictive equipment is purchased and put in place to help assess the maintenancerequirements in a more advanced

p2. Total Productive MaintenanceThe next stage of sophistication is Total Productive Maintenance and involvesalignment between Maintenance and Operations. In a TPM environment, lightmaintenance tasks (lubrication, cleaning and/or visual inspections) as performed bythe operators reduce the workload for the maintenance teams. If companies havereached this stage, they are often rR



8/10


3. Reliability Centered Maintenance.This is the fourth stage of sophistication and applies to those companies that havesuccessfully deployed an RCM program. Analysis and classification of equipment has

lead to the implementation of an RCM-based PM program where intervals have beenptimised.

. Implementing RCM using MAXIMO

XIMO to ensure that the maintenance teams receivee right instructions and work.

ig. 3 RCM MAXIMO Analysis

o

5

Organizations that deploy MAXIMO as their Strategic Asset Management solution,can use MAXIMO as the cornerstone of the RCM program. A lot of the base datarequired for an RCM analysis is stored in the MAXIMO database. Once the RCManalysis has been completed, the updated work instructions, PM intervals, criticalitycodes etc can be updated in MAthF

Thermo-

graphy

Mechanical

Integrity

Other

Oil

Sampling

Vibration

Analysis

Operator

rounds

RCM

Library

Peer review

& Approval

Analysis

Data

Collection

As built

Walkdowns

Data

Upload

Download from

MAXIMO:Locations

Equipment

PMs

Job Plans

Failure codes/lists

Long description

Value lists

Upload to

MAXIMO:Optimized PMs

Optimized Job Plans

Problem/cause/remedy

RCM Analytics

Condition Monitoring Programs

Each company tends to have their own definition of what is required to implement a

RCM-based maintenance programs and a

n

s a result of that, there are various toolsvailable to help support RCM projects.

IMO solution allow users to create user-pecific reports to support RCM projects.

de:nalysis (FMEA)

Event Tree Analysis (ETA)

aMAXIMO Reporting ToolsThe reporting tools that come with the MAXsOther reliability analysis and reporting tools inclu Failure Modes and Effect A Fault Tree Analysis (FTA)



9/10


MRO Software has established partnerships with several RCM-oriented partnersolutions such as DS&S, Meridium and Isograph. More information about these

ompanies can be found at:

http://www.mro.com/corporate/partners/programs_industry.htm

c

capturing the optimised PMs and Job Plans once theRCM program is put in place.

. Customer case

of 14illion kilowatts and 9 million acres of land and numerous supporting assets.

of an

ow lists the changes in PM requirements as a result of therogram.

M Reqd PM Reqd hange

MAXIMO serves as the system of record for the RCM program by first providing thebasis for analysis and later on

6

The Bureau of Reclamation (BOR) was created in 1902 to develop agriculturaleconomies in the Western States of the United States of America. The BOR has builtand now operates 348 reservoir facilities in 17 states. It is the largest water provider,

the 2ndlargest producer of hydro-electric power and the 9thlargest power utility in theUnited States. Its assets include 58 powerplants, 192 generators with capacitymThe Bureau of Reclamation is a long time MAXIMO user. Its implementationRCM-based maintenance program has led to a 71% reduction in scheduledmaintenance. The table belp

Labor resources Old P New % C

Control operators 312 312 0%

Plant mechanics 718 369 -49%

Electricians 1440 113 -92%

C&I Technicians 468 26 -95%

Electrical engineers 0 16 +100%

Maintenance 0 2 +100%workers

Total (# of workrders)

2937 837 -71%o

The BOR uses a third-party software product to upload information from MAXIMO toanalyse the information from an RCM perspective. Once completed, they optimisedthe records in MAXIMO again to drive the work planning for the maintenance crews.

. Conclusions

improve

ndation of data and process support required tochieve results from the program.

and patterns that frees upsources that can be used to start up an RCM program.

7

RCM is a best practice that maintenance departments can implement toreturn on investment in assets. Systems like MAXIMO support an RCMimplementation and provide the fouaWith MAXIMO, customers can develop the initial levels of sophistication that movethe organization from a reactive fire-fighting mode to a more proactive maintenanceapproach. The transition will lead to a shift in the workloadre



10/10



Furthermore, MAXIMO serves as the system of record for the RCM program by firstproviding the basis for analysis and later on capturing the optimised PMs and JobPlans once the RCM program is put in place.

8. About MRO Software

MRO Software is a leading provider of e-Business solutions for strategic assetmanagement.

The Companys integrated suite of applications optimizes performance, improvesproductivity and service levels and enables asset-related sourcing and procurementacross the entire spectrum of strategic assets.

The Companys asset management solutions allow customers to manage thecomplete life cycle of strategic assets, including planning, procurement, deployment,tracking, maintenance and retirement.

Using MRO Softwares solutions, customers improve production reliability, laborefficiency, material optimization, software license compliance, lease management,warranty and service management and provisioning across the asset base.

MRO Software (Nasdaq: MROI) is a global company based in Bedford, MA, withapproximately 1,000 employees. The Company markets its products through a directsales organization in combination with a network of international distributors. MROSoftware has sales offices throughout North America, Europe, Asia/Pacific and LatinAmerica. Additional information on MRO Software can be found athttp://www.mro.com.

MRO SoftwareTM is a trademark of MRO Software, Inc.

9. Sources:

Reliability Centered Maintenance, John Moubray, Second Edition, Industrial Press,1997, 1992

Populating MAXIMO with RCM Results, Larry Johnson, Fractal Solutions,presentation at MWUG, Sept 10/11, 2002

rcm ala maximo

Documents