What are the best practices for applying reliability centered maintenance (RCM) in your industry?

Uma sugest?o nada convencional para determinar a prioriza??o da aplica??o da análise RAM, é o entendimento do propósito do processo. Um processo pode ser observado externamente e trazer um entendimento superficial através de uma análise baseada puramente em literatura. Quando entendemos a fundo o propósito de cada componente e sua responsabilidade dentro do todo, os resultados das análises devem ser interpretados e estudados para garantir maior eficiência sobre a demanda do processo especificamente sobre aquele ativo ou sistema.

In order to be able to implement RCM for a technical product, you'll need to start a sound reliability and safety program at the start of your design. When you integrate the different RAMS engineering methods, you have a sound basis for building RCM. You'll need item-FMECA as well as design FMECA in order to be able to identify Maintenance Critical Items.

one thing I've found helpful is to use 'Oreda' to identify probable failure modes which effect on equipment and component function also you can define its failure rate specially sometimes we do not have enough data to know it , after you identifying failure modes you need to list down causes for each ,regards the criticality analysis or ranking we have two methods , qualitative using RPN 'Risk Priority Number'& quantitative using L,M,H analysis, until that you considered made FMECA ,next you need to continue to complete RCM by using causes mentioned before to define mitigation tasks for each failure mode with its interval, by this manner we can do great output from study valid to enhance efficiency and effectiveness of maintenance strategy

A good RCM requires experience, knowledge about the equipment and data. However, data is a very broad term and should be properly defined before investing too much time into something that won't add value to the method. An asset hierarchy, a criticality analysis and root cause analysis reports are necessary information to have about the asset you are performing the study. Having a Bill Of Materials may help in case you don't have a fully developed Asset Hierarchy, but it will increase pre analysis time before you jump into the RCM exercise. For the Criticality Analysis, you can define the critical functions. Most recent studies recommend that criticality should be treated as a dynamic factor using inputs from different stakeholders.

The challenge I've faced many times when doing an RCM is the balance between over-prescribers and risk-takers. There is no silver bullet, you may have a very conservative maintenance strategy and suffer a catastrophic failure. However having a well defined risk matrix where failure rate, severity and cost-benefit are considered can help you to have a standardized and agreed criteria. Critical functions (which are directly related to production) should have its failure modes properly monitored and depending on the severity more effective ways to eliminate the failure modes should be implemented, as redundancies, for example, also equipment parameters should be explored as much as possible to track patterns.

When using Failure Mode and Effects Analysis (FMEA) to select the right maintenance strategy, prioritize critical failure modes with high severity and occurrence ratings. Evaluate existing maintenance approaches and select preventive, predictive, condition-based, or reliability-centered maintenance strategies that effectively mitigate these critical failure modes while optimizing cost, performance, and risk. Periodically review and update the maintenance strategy based on new insights from FMEA and ongoing performance data for continued effectiveness.

Most manufacturers have a deeply stablished strategy to face their maintenance efforts. The root of the decision lie in the go-to-market strategy: is the product at hand selling as an easy-to-maintain asset or on the contrary, are they strengths based elsewhere? In any case, in industries such as Aerospace, stablished methodologies such as MSG-3 (Maintenance Steering Group 3) provide a structured approach that standarises RCM efforts for the whole industry and ensures no product is behind in their RCM efforts.

As much as the proper performance of maintenance activities is important and valuable, proper maintenance should also be emphasized, and managers and organizations should allocate time and resources for it. This process, which needs to be repeated periodically based on the requirements and new conditions of the equipment.

Maintenance strategy is output from RCM when we handle maintenance strategy, we need to think about shifting from TBM 'time based maintenance' to CBM 'condition based Maintenace' and 'RTF run to fail maintenance' , that make RCM successful when you depend by big % on CBM as a maintenance strategy, that because the majority of the failure happened randomly not by age, that is very clear at six failure patterns percentages. on other hand as a holistic view, we shift majority of TBM tasks to CBM and some to RTF. definitely when make RCM and catch failures in early-stage due dependence on CBM as new strategy that will cut cost of spare parts , manhours, downtime; the same as happened from shifting from TBM to RTF.

Implementing a maintenance plan based on reliability and critical items is a task where vast amounts of data ar handled. From item, to system to product integration all maintenance intervals need to be harmonized. To handle such quantity of data in a structured there are interesting pieces of software in the market such as PTC Windchill or, when looking for a specific tool in aerospace to apply MSG-3, Robin RAMS is a good ally.

in my experience its very easy to track effectiveness of your new maintenance strategy by using some key performance indicators to compare before and after new Maintenace strategy impact on business and financials to assure that you fill the gaps in your old strategy like downtime, total assets availability, MTBF, MTTR, OEE, maintenance cost as a percentage of replacement asset value 'RAV', backlog of maintenance work order, Emergency maintenance %, spare parts inventory turnover.

Yes, based on operating history of Particular equipment, Maintenance Plans to be reviewed from time to time. Some times the Equipment operating conditions may vary depending on site conditions which may not be captured by the original equipment manufacturers in their suggested maintenance schedules, requires legitimate correction.

There are many things that can trigger a maintenance plan review and update. I personally don't think a periodical review is recommended. I've done it before and I believe it is a waste of time. Instead, you should use indicators to trigger this review, in my opinion the most relevant indicators to define if a specific job plan, or even a whole maintenance plan or strategy should be reviewed are: - Hours dedicated to Unplanned Maint. / Hours dedicated to Planned Maint. (Planned Corrective Maint. + Preventive Maint. + Predictive Maint. + Operator Care or Autonomous Maint.) ratio. If you track this metric by Asset/Assembly/Component (ideally by Failure Mode) you can trigger your maintenance plan evaluation when it gets over 10%.

Eu uso como boa prática Revisar meus estudos de RCM a cada dois anos, pois ao longo desse período, mudan?as substanciais podem ocorrer na planta, porquê: 1- O contexto operacional pode mudar, com o aumento constante do volume de produ??o, demandando mais dos equipamentos, 2- As equipes de técnicos e engenheiros de manuten??o também podem mudar 3- as frequências previstas inicialmente podem n?o estar surtindo o resultado esperado, o que me permite avaliar a eficácia dos planos criados no estudo de RCM, observando se reduziram falhas, ampliaram o tempo médio entre falhas etc. Essa prática é essencial para garantir a eficiência contínua do sistema.

In my experience you need to review and re-do RCM to update your maintenance strategy and plan each 5 years due to latest technology that will appear, new failure mode explored, equipment aging and wear, change in operating condition through time, new feedback from Maintenace activities, changing in safety and regulation standard as well as adaptation with new business goals. so , due to all above mentioned variables we need to review and update our Maintenace plan which conducted from our RCM.

one time at work in a RCFA committee meeting on a centrifugal pumps we have a problem with main bearing which is fail early and that repeated , we starting RCFA we find solution and implement it with no solving for the problem, finally we find that the operator changed the oil types due to shortage of the right oil type and this is his responsibility and they afraid to say ,so they use another types and at RCFA meeting didn't say anything related , so Reliability culture is a long journey ,you need to enrich reliability thinking and try to make all technical department speaking reliability , and understand the impact of each point missing or did wrongly on the equipment condition then on the cost and then on business interruption.

New methodologies of data analysis are paramount to improve the classical RCM approaches to a strongly preventive maintenance based system such as, for instance, MSG-3. In the aerospace industry, HUMS systems that collect field data for diagnosis and prognosis have been getting the attention of R&D programs for long. However, the criticality and the high safety standards of the industry, make the implementation of these innovations slow. It is yet to see how Predictive Maintenance can make its way into Maintenance Programs which are so heavily monitored by the certification entities.

It is a no-brainer, to achieve better financial results you should be able to extract the most out of your asset. In order to reduce asset unavailability which can be translated as red money, catch defects and failures before they happen is mandatory. Out of all the options to evaluate your asset performance the continuous monitoring of equipment parameters is continuously getting cheaper and easier to capture data and generate insights that can be converted into defect identification. The challenges here are: - Manage the amount of data generated - Ensure Data Integrity and Quality - Use the experience and operational knowledge to develop statistical models that can transform insights into action triggers

Conduzir estudos de RCM, só pelo fato de ser uma ferramenta de confiabilidade, pode fazer com que o resultado da manuten??o n?o seja a “tal redu??o dos Hhs e/ou garantida da disponibilidade dos ativos”. Para implementar o RCM e ter resultados reais, tenha clareza que você precisará: 1- ter uma hierarquiza??o dos seus ativos ( sabendo suas fun??es básicas ) 2- ter histórico dos ativos, pois nos dias atuais usar RCM de forma subjetiva ou somente usando a experiência já n?o tem gerado muito resultado 3- tenha um PCM forte e com pessoas que conhe?am os ativos 4- realmente tenha os matérias sobressalentes para os ativos, e o principal : 5- tenha o contexto operacional definido, pois irá reduzir muito a margem de erro do estudo.

Don’t even think about doing an RCM if you don’t have a Maintenance Planning and Scheduling in place. And by P&S, I mean having a Planner planning your shoutdowns, planning the planned maintenance at least 2 weeks in advance. I mean having a Scheduler scheduling the planned maintenance at least a week in advance. And, having indicators: PM compliance, Schedule breaker details, Corrective and PM Ratio, etc. Why? Because if you do, the Resource Consuming Monster (cute nickname for RCM) will throw in the trash (in a report format) hundreds of hours of highly skilled personnel. A new maintenance strategy resulted from an RCM can be stored and used later, but it is highly correlated to operational context, so apply it right away is recommended.

Best practices for RCM involve identifying critical assets, analyzing failure modes, and implementing preventive maintenance. In offshore wind power, RCM ensures optimal performance by focusing on key components like turbines, mitigating risks of downtime due to failures. Grid code compliance studies utilize RCM to maintain transmission infrastructure, preventing grid instability. In manufacturing, RCM maximizes uptime by prioritizing maintenance on crucial machinery. For battery energy storage, RCM enhances system reliability through proactive monitoring and maintenance of cells and control systems.

In the ash handling industry, RCM best practices dictate a proactive approach. Begin with a detailed analysis of each asset, identifying critical components and potential failure modes. Employ predictive maintenance techniques, such as vibration analysis or thermography, to monitor equipment condition. Prioritize maintenance activities based on risk assessments, focusing on high-impact areas. Train personnel thoroughly in RCM methodologies to ensure a deep understanding of the processes. Regularly review and adjust maintenance plans based on performance data, striving for continuous improvement. This strategic application of RCM will lead to enhanced reliability, efficiency, and cost savings in the long run.