How do you use RGM to prioritize RCM tasks?

1 Identify the assets and their functions

The first step is to identify the assets and their functions that are relevant for RCM. You can use a functional hierarchy or a system diagram to organize the assets into logical groups and subgroups. For each asset, you should define its primary function, its performance standards, and its functional failures. A functional failure is a deviation from the performance standard that affects the asset's ability to deliver its function.

2 Analyze the failure modes and their consequences

The second step is to analyze the failure modes and their consequences for each asset. A failure mode is a specific way that an asset can fail to perform its function. You can use a failure mode and effects analysis (FMEA) or a failure mode, effects, and criticality analysis (FMECA) to identify the potential failure modes, their causes, their effects on the asset and the system, and their criticality. The criticality of a failure mode is a measure of its impact on the safety, environment, production, quality, or cost of the system.

3 Evaluate the risk of each failure mode

The third step is to evaluate the risk of each failure mode using a risk matrix or a risk model. Risk is a combination of the probability and the consequence of a failure mode. You can use historical data, expert judgment, or reliability models to estimate the probability of each failure mode. You can use the criticality ratings, the severity categories, or the cost-benefit analysis to estimate the consequence of each failure mode. The risk matrix or the risk model will help you rank the failure modes according to their risk level and assign them to different risk categories.

4 Select the appropriate maintenance strategy for each failure mode

The fourth step is to select the appropriate maintenance strategy for each failure mode based on the risk level and the failure characteristics. You can use a decision logic tree or a decision matrix to guide you in choosing the best maintenance strategy. The main types of maintenance strategies are run-to-failure (RTF), which is suitable for low-risk and low-cost failure modes that are unpredictable or unavoidable; preventive maintenance (PM), which is suitable for moderate-risk and moderate-cost failure modes that are predictable or preventable; predictive maintenance (PdM), which is suitable for high-risk and high-cost failure modes that are detectable or avoidable; and proactive maintenance (PAM), which is suitable for chronic or recurring failure modes that are correctable or avoidable.

5 Plan and schedule the maintenance tasks

When planning and scheduling maintenance tasks, you should take into account the priority of the task based on the risk level of the failure mode, the frequency of the task based on the reliability of the asset or condition threshold, and the duration of the task based on complexity and scope of work. Additionally, you should consider what resources are needed for the task, such as labor, materials, tools, equipment, and spare parts. Furthermore, you should be mindful of any constraints or dependencies that may affect the task, such as safety regulations, availability of access, permits required, and coordination with other teams.

6 Monitor and review the maintenance performance

The sixth step is to monitor and review the maintenance performance and adjust the RCM plan as needed. To measure and evaluate the effectiveness and efficiency of the maintenance tasks, you should use key performance indicators (KPIs) and reliability metrics such as availability, reliability, maintainability, maintenance cost, and maintenance benefit. Additionally, collecting and analyzing the feedback and data from the maintenance tasks can help identify gaps, issues, or opportunities for improvement. This way, you can update the RCM plan to optimize the maintenance activities and reduce the risks.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?