RELIABILITY CENTRED MAINTENANCE (RCM)
Application within RCAF and Implementation in OmegaPS
Mike Martin
OMUG 2013 M. Martin 2
BRIEFING OUTLINE
Maintenance Environment within RCAF
RCM Process (MSG-3)– Principles of RCM– Significant Item Selection– Functional FMEA– Level 1 & 2 Decision Logic– Task Assignment and Packaging
Implementation in OmegaPS (FRCM)
OMUG 2013 M. Martin 3
MAINTENANCE ENVIROMENT WITHIN RCAF
• Maintenance Program part of Design• Changes tightly regulated• Conduct of Maintenance on aircraft /
equipment recorded and controlled• Support to Legacy fleets becoming more
challenging
OMUG 2013 M. Martin 4
WHAT IS RCM?A Definition:– RCM is a structured process to identify the appropriate level
of preventive maintenance for an item to:• Retain inherent levels of performance, reliability and
safety• Minimize cost of maintenance and failures over the life
cyclePrimary Objectives:– Ensure safety through PM actions; when PM cannot
effectively ensure safety, redesign is mandatory– When safety is not a concern, preserve functionality in the
most economical manner with the least impact on Operations
OMUG 2013 M. Martin 5
WHY DO RCM?New Programs:
– Requirement of design (ICAs)– Identify APPLICABLE and EFFECTIVE scheduled
maintenance tasks– Initial programs conservative and generic
Legacy Programs:– Able to modify generic programs to suit
environment and fleet performance– Structured, disciplined approach to substantiating
proposed Design Changes
OMUG 2013 M. Martin 6
FLAVOURS OF RCM
ATA/MSG-3 (***)RCM II
NAVAIR 00-25-403 NAVSEA S9081-AB-GIB-010
DEF STAN 02-45Etc
If any question about whether or not a process meets RCM requirements consult:
SAE JA1011 – Evaluation Criteria for RCM Processes
OMUG 2013 M. Martin 7
STEPS TO PERFORM RCM
Step 1: Identify MSIStep 2: Perform Functional FMEAStep 3: Apply MSG-3 Decision Logic
Level 1 – Failure Effect Code
Level 2 – Task IdentificationStep 4: Package Maintenance Tasks
OMUG 2013 M. Martin 8
MAINTENANCE SIGNIFICANT ITEMS(MSIs)
– Objective of MSI selection: select appropriate systems / components for analysis
– Why be selective?• A/C equipment and systems have many components and
parts• Analysis of every component on an aircraft would be
unrealistically costly and time consuming• Failure of many items have no immediate impact on the
a/c as a whole– RCM derived maintenance program directs tasks
where they matter – at Significant Items
OMUG 2013 M. Martin 9
– Partition equipment into major functional areas
– Top-down approach; identify items at highest manageable level
– Item is MSI if failure could:• adversely effect safety• Have major operational or economic consequences• Be undetectable during normal operations
– If in doubt, item should be selected as an MSI
STEP 1 – IDENTIFY MSIs
OMUG 2013 M. Martin 10
PARTITION EQUIPMENT
WEAPON SYSTEM
SYSTEM
SUB SYSTEM
SYSTEM
SUB SYSTEM SUB SYSTEM
LRU LRU LRULRU
OMUG 2013 M. Martin 11
ITEM FROM ECIR
DOES ITEM HAVE CURRENT TASK OTHER THAN REMOVE FOR ACCESS?
IS ITEM STRUCTURE ?RETAIN TASK
YES YES
IDENTIFY AS NON-MSI
NO
MSG-3ANALYSIS
COULD FAILURE BE HIDDEN OR NOT LIKELY TO BE DETECTED BY THE OPERATING CREW DURING
NORMAL DUTIES?
COULD FAILURE AFFECT SAFETY(ON GROUND OR IN FLIGHT) INCLUDING SAFETY/EMERGENCY
SYSTEMS OR EQUIPMENT?
COULD FAILURE HAVE A SIGNIFICANT ECONOMIC IMPACT?
COULD FAILURE HAVE A SIGNIFICANT OPERATIONAL IMPACT?
YES
YES
YES
YES
NO
NO
NO
NO
IDENTIFY AS NON-MSI
NO
NO
MSI 1
MSI 7
MSI 3
MSI 2
MSI 6
MSI 5
MSI 4
IDENTIFY AS MSI
YES
DOES STRUCTURE ITEM HAVE CURRENT TASK OTHER THAN REMOVE
FOR ACCESS?
MSI SELECTION DECISION LOGIC
OMUG 2013 M. Martin 12
INDENTIFY FUNCTIONWhat are the normal characteristics of the
MSI?
How does the MSI fail to perform this
function?
ARE THERE ADDITIONAL FUNCTIONS
?
YES
IDENTIFY FUNCTIONALFAILURE
ARE THERE ADDITIONAL
FUNCTIONALFAILURES
?
YES
FOR EACH FUNCTION
NO
INCREMENT IDENTIFICATION FOR
EACH FUNCTION(eg. 1,2…)
INCREMENT IDENTIFICATION FOR EACH FUNCTIONAL
FAILURE(eg. 1A, 1B …)
FOR EACH FUNCTIONALFAILURE
IDENTIFY FUNCTIONAL FAILUREEFFECT
What happens when this functional failure
occurs?
IDENTIFY FUNCTIONAL FAILURECAUSE(S)
NO
ARE THERE ADDITIONAL
FAILURE EFFECTS?
INCREMENT IDENTIFICATION
FOR EACH FUNCTIONAL
FAILURE EFFECT(eg. 1A1, 1A2 …)
YES
FOR EACH FAILURE EFFECT
ARE THERE ADDITIONAL
FAILURE CAUSES?
INCREMENT IDENTIFICATION
FOR EACH FAILURECAUSE
(eg. 1A1A, 1A1B …)
YES
END FMEA
NO
NO
STEP 2 - FUNCTIONAL FMEA
OMUG 2013 M. Martin 13
RESULTS OF FMEA
For each MSI:- List of High Level Functions
For each Function:- List of Functional Failures
For each Functional Failure:- List of Failure Effects
For each Failure Effect:- List of Components which cause this
Functional Failure/Failure Effect to Occur
OMUG 2013 M. Martin 14
EXAMPLE OF FMEA
EXAMPLE ONLY
OMUG 2013 M. Martin 15
STEP 3 – APPLY MSG-3 DECISION LOGIC
LEVEL 1 – Identification of Functional failure Effect (FEC)
LEVEL 2 – Identification of APPLICABLE and EFFECTIVE Preventive Maintenance Task
OMUG 2013 M. Martin 16
MSG-3 LEVEL 1 & 2 DECISION LOGIC
OMUG 2013 M. Martin 17
LEVEL 1 DECISION LOGIC
OMUG 2013 M. Martin 18
LEVEL 2 DECISION LOGICIS A LUBRICATION OR SERVICING TASK APPLICABLE & EFFECTIVE?
5A
LUBRICATION/SERVICING
INSPECTION/FUNCTIONAL CHECK
RESTORATION
DISCARD
IS DISCARD TASK TO AVOID FAILURES OR REDUCE THE FAILURE RATE
APPLICABLE & EFFECTIVE?
5D
IS RESTORATION TASK TO REDUCE FAILURE RATE APPLICABLE &
EFFECTIVE?
5C
IS AN INSPECTION OR FUNCTIONAL CHECK TO DETECT DEGREDATION OF FUNCTION APPLICABLE & EFFECTIVE?
5B
IS THERE A TASK OR COMBINATION OF TASKS APPLICABLE & EFFECTIVE?
5E
NOYES
YES
YES
YES
YES
NO
NO
NO
NO
REDESIGN IS MANDATORY
TASK/COMBINATION MOST EFFECTIVE MUST BE DONE
IS A LUBRICATION OR SERVICING TASK APPLICABLE & EFFECTIVE?
6A
LUBRICATION/SERVICING
INSPECTION/FUNCTIONAL CHECK
RESTORATION
DISCARD
IS DISCARD TASK TO AVOID FAILURES OR REDUCE THE FAILURE RATE
APPLICABLE & EFFECTIVE?
6D
IS RESTORATION TASK TO REDUCE FAILURE RATE APPLICABLE &
EFFECTIVE?
6C
IS AN INSPECTION OR FUNCTIONAL CHECK TO DETECT DEGREDATION OF FUNCTION APPLICABLE & EFFECTIVE?
6B
NOYES
YES
YES
YES
NO
NO
NO
REDESIGN MAY BE DESIREABLE
OMUG 2013 M. Martin 19
EXAMPLE OF LEVEL 1 / 2
EXAMPLE
ONLY
OMUG 2013 M. Martin 20
STEP 4 – TASK PACKAGING
Select Significant Intervals
Fit Others into this interval or multiples
Group Individual Tasks Together By:- Location- Trade- Complexity- Frequency
OMUG 2013 M. Martin 21
SAMPLE INSPECTION CARD
OMUG 2013 M. Martin 22
Inspection Tasks (4 trades)
TYPICAL INSPECTION
OMUG 2013 M. Martin 23
CURRENT TOOLS
• AEPM Performa– ADAM data from the field– Extracted into Excel files
• Maintenance Analyzer (ATESS)– Access Database
• MSI• FMEA• Level 1 / 2 analysis
• Audit– MS Excel
OMUG 2013 M. Martin 24
CURRENT TOOLS
• Card Deck– Access Database– MS Word Templates– Contactor Database (IETM)– ????
• Scheduling / Planning– MS Project / MS Excel– Paper– ????
OMUG 2013 M. Martin 25
FUNCTIONAL RCM (FRCM)IN OmegaPS
OMUG 2013 M. Martin 26
FRCM MODULE
• Create FUNCTIONAL structure• MANAGE analysis assignments• Perform FMEA• Audit FMEA • Perform Level 1 / Level 2 analysis• Assign Task and Interval• Audit Level 1 / Level 2 and Task analysis
OMUG 2013 M. Martin 27
CREATE FUNCTIONAL STRUCTURE
OMUG 2013 M. Martin 28
SELECT FUNCTIONAL RCM MODULE
OMUG 2013 M. Martin 29
FUNCTIONAL TREE STRUCTURE
OMUG 2013 M. Martin 30
MANAGER
OMUG 2013 M. Martin 31
DEVELOP FMEA
OMUG 2013 M. Martin 32
OmegaPS FMEA Worksheet
OMUG 2013 M. Martin 33
LEVEL 1 ANALYSIS
OMUG 2013 M. Martin 34
LEVEL 2 ANALYSIS
OMUG 2013 M. Martin 35
LEVEL 1 / LEVEL 2 REPORT
OMUG 2013 M. Martin 36
TASK / INTERVAL IDENTIFICATION
OMUG 2013 M. Martin 37
POTENTIAL OmegaPS MODULE INTEGRATION
FRCM
ANALYZER
PoM
PUBLISHER
LORA
Questions?
Top Related