C1-1(Intro)

INTRODUCTION TO RCMINTRODUCTION TO RCMINTRODUCTION TO RCMINTRODUCTION TO RCM

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UNIT IUNIT I


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IntroductioIntroductionn


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IntroductionIntroduction IntroductionIntroduction

RCM DefinedRCM Defined RCM DefinedRCM Defined

RCM ReferencesRCM References RCM ReferencesRCM References

Review and SummaryReview and Summary Review and SummaryReview and Summary

History of RCMHistory of RCM History of RCMHistory of RCM

Benefits of RCMBenefits of RCM Benefits of RCMBenefits of RCM


Module Objective:Module Objective:Module Objective:Module Objective:

This module will provide an overview of This module will provide an overview of

Reliability-Centered Maintenance (RCM):Reliability-Centered Maintenance (RCM):

1. Provide a definition of Reliability-Centered 1. Provide a definition of Reliability-Centered MaintenanceMaintenance

2. Describe the history of RCM2. Describe the history of RCM

3. Identify the benefits of RCM3. Identify the benefits of RCM

4. Provide RCM reference materials4. Provide RCM reference materials



Before focusing on the details of how to Before focusing on the details of how to perform a Reliability-Centered Maintenance perform a Reliability-Centered Maintenance (RCM) analysis, it is useful to understand …(RCM) analysis, it is useful to understand …

• What RCM isWhat RCM is• Where it came fromWhere it came from• What benefits it provides andWhat benefits it provides and• What part it plays in a maintenance programWhat part it plays in a maintenance program


What is RCM ?What is RCM ?What is RCM ?What is RCM ? IntroductioIntroductionn


Reliability-Centered Maintenance (RCM) Reliability-Centered Maintenance (RCM)

An analytical process used to determine An analytical process used to determine appropriate failure management strategies appropriate failure management strategies to ensure safe and cost-effective operations to ensure safe and cost-effective operations of a physical asset in a specific operating of a physical asset in a specific operating environment.environment.

Failure Management strategiesFailure Management strategies• Preventive Maintenance (PM) requirements Preventive Maintenance (PM) requirements • Other actionsOther actions• Run to failureRun to failure

RCM DefinedRCM DefinedRCM DefinedRCM Defined


What is RCM?What is RCM?What is RCM?What is RCM?

• Goal of RCMGoal of RCM• Avoid or reduce failure Avoid or reduce failure CONSEQUENCESCONSEQUENCES• Not necessarily to avoid failuresNot necessarily to avoid failures

• Failure Consequences are the effects of Failure Consequences are the effects of failure onfailure on::

• Personal and Equipment SafetyPersonal and Equipment Safety• Environmental Health/ComplianceEnvironmental Health/Compliance• OperationsOperations• EconomicsEconomics




• Currently there are many processes Currently there are many processes that call themselves RCMthat call themselves RCM

• SAE JA1011 provides criteria to SAE JA1011 provides criteria to distinguish processes that follow the distinguish processes that follow the original tenets of RCMoriginal tenets of RCM

• This course is based on the RCM This course is based on the RCM methodology defined in NAVAIR 00-25-methodology defined in NAVAIR 00-25-403403





SAE JA1011 “Evaluation Criteria for RCM SAE JA1011 “Evaluation Criteria for RCM Processes” defines seven questions for RCM:Processes” defines seven questions for RCM:

• What are the functions…of the asset…(functions)?What are the functions…of the asset…(functions)?

• In what ways can it fail…(functional failures)?In what ways can it fail…(functional failures)?

• What causes each functional failure (failure modes)?What causes each functional failure (failure modes)?

• What happens when each failure occurs (failure effects)?What happens when each failure occurs (failure effects)?

• In what way does each failure matter (failure In what way does each failure matter (failure

consequences)?consequences)?

• What should be done…(proactive tasks and intervals)?What should be done…(proactive tasks and intervals)?

• What should be done if a suitable proactive task cannot What should be done if a suitable proactive task cannot

be found?be found?

Also requires a “Living Program”Also requires a “Living Program”

What is RCM?What is RCM?What is RCM?What is RCM? RCM DefinedRCM DefinedRCM DefinedRCM Defined


NAVAIR RCM Process as defined in NAVAIR RCM Process as defined in NAVAIR 00-25-403 meets SAE JA1011NAVAIR 00-25-403 meets SAE JA1011

• Built on FMECA and Failure Consequence Built on FMECA and Failure Consequence determinations (questions 1 through 5)determinations (questions 1 through 5)

• Establishes task and interval evaluation process Establishes task and interval evaluation process (question 6)(question 6)

• Considers “other actions” and “No PM” (question Considers “other actions” and “No PM” (question 7)7)

• Requires RCM Sustainment and Age Exploration Requires RCM Sustainment and Age Exploration (Living Program)(Living Program)

RCM DefinedRCM DefinedRCM DefinedRCM DefinedWhat is RCM?What is RCM?What is RCM?What is RCM?

NAVAIR 00-25-403 RCM process:NAVAIR 00-25-403 RCM process: Evolved over nearly 30 yearsEvolved over nearly 30 years Used in on a variety of equipment Used in on a variety of equipment

in various applicationsin various applications Continuously improvedContinuously improved

NAVAIR RCM Steering CommitteeNAVAIR RCM Steering Committee Complies withComplies with SAE JA1011SAE JA1011 Public DomainPublic Domain



Which Process?Which Process?Which Process?Which Process?


History of RCM History of RCM History of RCM History of RCM RCM History:RCM History:RCM History:RCM History:

• Early PM Programs based on Early PM Programs based on concept that periodic overhauls concept that periodic overhauls ensured reliability and, ensured reliability and, therefore, safetytherefore, safety

Overhaul: Tearing down and Overhaul: Tearing down and rebuilding componentsrebuilding components



• 1960s: 1960s: • Introduction of 747, DC-10, L-Introduction of 747, DC-10, L-

1011 led airlines to conclusion 1011 led airlines to conclusion that current preventive that current preventive maintenance philosophies were maintenance philosophies were unsustainableunsustainable

• FAA and Commercial Aviation FAA and Commercial Aviation Industry formed a group to study Industry formed a group to study preventive maintenancepreventive maintenance



• 1960s: (continued)1960s: (continued)

• FAA/Airline Group conclusion: FAA/Airline Group conclusion: overhauls had little or no effect overhauls had little or no effect on overall reliability or safety in on overall reliability or safety in many casesmany cases

• Why?Why?

Con

dit

ion

al P

rob

ab

ilit

yof

Failu

re

Time

Overhaul interval

What the airlines discoveredWhat the airlines discovered Statistical analysis showed, in most cases, no change in Statistical analysis showed, in most cases, no change in

safety or reliability when overhaul limits changed.safety or reliability when overhaul limits changed. Initial overhaul limits were not analytically based.Initial overhaul limits were not analytically based. High repair costs for little or no benefits.High repair costs for little or no benefits.

Facts about overhaulsFacts about overhauls Many failure modes do not support overhaul philosophy- Many failure modes do not support overhaul philosophy-

have no ‘right’ overhaul time.have no ‘right’ overhaul time. Lose considerable component life.Lose considerable component life. Overhauls re-introduce infant mortality failures.Overhauls re-introduce infant mortality failures.


RCM History:RCM History:RCM History:RCM History: History of RCM History of RCM History of RCM History of RCM


WEAR OUT CURVESWEAR OUT CURVES

Wear Out curves with Wear Out curves with potential benefit from potential benefit from overhauloverhaul

UAL Broberg MSPUAL Broberg MSP1968 1973 19821968 1973 1982UAL Broberg MSPUAL Broberg MSP1968 1973 19821968 1973 1982

4%4% 3%3% 3%3%4%4% 3%3% 3%3%

2%2% 1%1% 17%17%2%2% 1%1% 17%17%

5%5% 4%4% 3%3%5%5% 4%4% 3%3%

7%7% 11%11% 6%6%7%7% 11%11% 6%6%

14%14% 15%15% 42%42%14%14% 15%15% 42%42%

68%68% 66%66% 29%29%68%68% 66%66% 29%29%

Wear Out curves without Wear Out curves without potential benefit from potential benefit from overhauloverhaul

Ranges from Ranges from 8% to 23%8% to 23%

Ranges from Ranges from 77% to 92%77% to 92%

1965:1965: Studies show scheduled overhaul of complex Studies show scheduled overhaul of complex equipment has little or no effect on in-service reliabilityequipment has little or no effect on in-service reliability

1967-68:1967-68: Airline and manufactures form Maintenance Airline and manufactures form Maintenance Steering Group (MSG) and produceSteering Group (MSG) and produce MSG 1MSG 1, , “ Handbook: “ Handbook: Maintenance Evaluation and Program Development.” Maintenance Evaluation and Program Development.” First applied to Boeing 747First applied to Boeing 747

1970:1970: MSG handbook updated to MSG handbook updated to MSG-2MSG-2, , “Airline/ “Airline/ Manufactures Maintenance Program Planning Manufactures Maintenance Program Planning Document”. Applied to L-1011 and DC-10Document”. Applied to L-1011 and DC-10

1972:1972: MSG-2 techniques applied to NAVAIR systems (P- MSG-2 techniques applied to NAVAIR systems (P-3A, S-3A, and F-4J)3A, S-3A, and F-4J)



1975:1975: NAVAIR applied Analytical Maintenance Program NAVAIR applied Analytical Maintenance Program to Naval aircraft and engine programs, using MSG-2 to Naval aircraft and engine programs, using MSG-2 type logictype logic (NAVAIR 00-25-400)(NAVAIR 00-25-400)

1978:1978: Department of Defense (DOD) sponsored DOD Department of Defense (DOD) sponsored DOD report report AD-A066579AD-A066579, “Reliability Centered Maintenance” , “Reliability Centered Maintenance” by Nowlan and Heap - Updates MSG-2 approach with by Nowlan and Heap - Updates MSG-2 approach with better guidance on process and interval determination better guidance on process and interval determination

1980:1980: Army issued Army issued Army Pamphlet 750–40Army Pamphlet 750–40,, “Guide to “Guide to RCM for Fielded Equipment ” RCM for Fielded Equipment ”

1981:1981: DOD issued DOD issued MIL-HDBK-266MIL-HDBK-266, , “Application of RCM “Application of RCM to Naval Aircraft, Weapon Systems and Support to Naval Aircraft, Weapon Systems and Support Equipment” to implement RCM concepts from DOD Equipment” to implement RCM concepts from DOD report AD-A066579report AD-A066579



1983:1983: MSG-3 MSG-3 issued. Used in design of Boeing 757 and issued. Used in design of Boeing 757 and 767 aircraft. Added emphasis on structural inspection 767 aircraft. Added emphasis on structural inspection programs. Similar to RCM, but lacked guidance on interval programs. Similar to RCM, but lacked guidance on interval determinationdetermination

1985:1985: US Air Force (USAF) issued US Air Force (USAF) issued MIL-STD-1843MIL-STD-1843, , " RCM " RCM Requirements for Aircraft, Engines and Equipment“ - Requirements for Aircraft, Engines and Equipment“ - Similar to MSG-3 (Cancelled without replacement in 1995, Similar to MSG-3 (Cancelled without replacement in 1995, USAF Instructions contain current policy/guidance)USAF Instructions contain current policy/guidance)

1986:1986: NAVAIR issued NAVAIR issued MIL-STD-2173MIL-STD-2173, , "RCM Requirements "RCM Requirements for Naval Aircraft, Weapons Systems and Support for Naval Aircraft, Weapons Systems and Support Equipment". Superceded MIL-HDBK-266 & NAVAIR 00-25-Equipment". Superceded MIL-HDBK-266 & NAVAIR 00-25-400400

NAVAIR 0-25-403NAVAIR 0-25-403 issued containing Age Exploration issued containing Age Exploration guidance.guidance.

19921992: : Coast Guard issuedCoast Guard issued CGTO PG–85–00–30CGTO PG–85–00–30, , “Aeronautical Engineering Process Guide for RCM Process”“Aeronautical Engineering Process Guide for RCM Process”



RCM success in Aviation industry noted by other RCM success in Aviation industry noted by other industries - Nuclear Power and Space industries adopt industries - Nuclear Power and Space industries adopt approach due to focus on avoidingapproach due to focus on avoiding “safety “safety consequences”consequences”

““RCM II” by John Moubray published in UK in 1990RCM II” by John Moubray published in UK in 1990

““Reliability-Centered Maintenance” by Mac Smith Reliability-Centered Maintenance” by Mac Smith published in US in 1993published in US in 1993

As interest in increased, a variety of other processes As interest in increased, a variety of other processes called themselves “RCM”called themselves “RCM”

Industry interest in SAE JA1011 and JA1012 Industry interest in SAE JA1011 and JA1012 was to identify “valid” RCM approacheswas to identify “valid” RCM approaches



1996:1996: NAVAIR updatedNAVAIR updated NAVAIR 00-25-403NAVAIR 00-25-403 to contain to contain complete RCM process due to cancellation of MIL-SPEC’scomplete RCM process due to cancellation of MIL-SPEC’s

1999: 1999: SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) issued SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) issued SAE SAE JA1011JA1011, , “Evaluation Criteria for RCM Processes” - establishes “Evaluation Criteria for RCM Processes” - establishes criteria for RCM processes (NAVAIR and Aladon/John Moubray criteria for RCM processes (NAVAIR and Aladon/John Moubray major contributors)major contributors)

2001: 2001: NAVY updatedNAVY updated NAVAIR 00-25-403NAVAIR 00-25-403 to capture to capture improvements developed during SAE JA1011 work - provides improvements developed during SAE JA1011 work - provides primary guidance for implementing NAVAIR RCM program or primary guidance for implementing NAVAIR RCM program or performing RCM analysis (Current edition March 2003)performing RCM analysis (Current edition March 2003)

2002: 2002: SAE issuedSAE issued SAE JA1012SAE JA1012, , “A Guide to the RCM Standard” - “A Guide to the RCM Standard” - amplifies and clarifies key concepts and terms from SAE JA1011amplifies and clarifies key concepts and terms from SAE JA1011



If performed properly, RCM will:If performed properly, RCM will:• Maximize safety and environmental Maximize safety and environmental

healthhealth• Depending on objective:Depending on objective:

• Reduce overall maintenance cost Reduce overall maintenance cost • Improve realized reliability/availabilityImprove realized reliability/availability

• Provide a documentation trail for Provide a documentation trail for maintenance program changesmaintenance program changes

• Provide a vehicle for continuous Provide a vehicle for continuous improvement of the maintenance improvement of the maintenance program and equipment performanceprogram and equipment performance

RCM BenefitsRCM BenefitsRCM BenefitsRCM Benefits


Benefits of Benefits of RCMRCM

Benefits of Benefits of RCMRCM


RCM ReferencesRCM ReferencesRCM ReferencesRCM ReferencesReferences:References:References:References:

• NAVAIR RCM Website - This site provides easy access to NAVAIR RCM Website - This site provides easy access to Naval Air Systems Command (NAVAIR) RCM policies and Naval Air Systems Command (NAVAIR) RCM policies and tools.tools.

http://logistics.navair.navy.mil/rcmhttp://logistics.navair.navy.mil/rcm

• NAVAIR 00-25-403 - This manual covers pNAVAIR 00-25-403 - This manual covers planninglanning for RCM, for RCM, RCM RCM theorytheory and specific guidance for and specific guidance for performingperforming the the

analysis, and ianalysis, and implementingmplementing analysis results. analysis results. Available at NAVAIR WebsiteAvailable at NAVAIR Website

• SAE JA1011- This document is intended to be used toSAE JA1011- This document is intended to be used to evaluate any process that claims to be an RCM process. evaluate any process that claims to be an RCM process.

Available from SAE via webAvailable from SAE via web

• SAE JA1012 - A Guide to the Reliability-Centered SAE JA1012 - A Guide to the Reliability-Centered Maintenance Standard.Maintenance Standard.

Available from SAE via webAvailable from SAE via web


RCM ReferencesRCM ReferencesRCM ReferencesRCM ReferencesReferences:References:References:References:

• "Reliability-Centered Maintenance“- Stanley F. Nowlan "Reliability-Centered Maintenance“- Stanley F. Nowlan and and

Howard F. Heap of United Airlines.Howard F. Heap of United Airlines. Available from NTIS via webAvailable from NTIS via web

• RCM: Gateway to World Class Maintenance- Mac Smith RCM: Gateway to World Class Maintenance- Mac Smith & Glenn Hinchcliffe (2003)& Glenn Hinchcliffe (2003)

Available in book stores Available in book stores

• RCM II Reliability-centered Maintenance, 2RCM II Reliability-centered Maintenance, 2ndnd Edition- Edition- John Moubray 1997John Moubray 1997

Available in book storesAvailable in book stores


Review and SummaryReview and Summary Review and SummaryReview and Summary

• Overview of the Reliability-Centered MaintenanceOverview of the Reliability-Centered Maintenance (RCM) Process. (RCM) Process.

Module ObjectiveModule Objective


• Learning ObjectivesLearning Objectives

RCM OverviewRCM Overview

• RCM DefinitionRCM Definition• Benefits of RCMBenefits of RCM• HistoryHistory• ReferencesReferences

End of Module up next……..

NAVAIR RCM Policy & Organization

End of Module up next……..

NAVAIR RCM Policy & Organization

C1-1(Intro)

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