{"id":7224,"date":"2019-07-10T15:30:34","date_gmt":"2019-07-10T15:30:34","guid":{"rendered":"https:\/\/www.aroraengineers.com\/?p=7224"},"modified":"2019-07-10T15:31:56","modified_gmt":"2019-07-10T15:31:56","slug":"what-is-rcm-and-how-do-you-get-there","status":"publish","type":"post","link":"https:\/\/www.aroraengineers.com\/what-is-rcm-and-how-do-you-get-there\/","title":{"rendered":"What is Reliability Centered Maintenance (RCM) and How Do You Get There?"},"content":{"rendered":"
\n
\n

What is RCM?<\/h2>\n

Reliability centered maintenance (RCM) is a study in how to balance requirements using risk-ranking, optimized maintenance strategies, and focusing on worst offenders. RCM analysis is a review process to preserve a system\u2019s function by identifying likely failure modes and assigning feasible proactive tasks. This overall strategy helps stakeholders work on the right asset, with the right strategy, at the right time, by the right resource, at the least cost. If this strategy succeeds, there should be less unplanned work – meaning less equipment failures.<\/p>\n

But How Do You Get There?<\/h2>\n

Being an advanced process, there are several steps to \u201cget there\u201d:<\/p>\n

    \n
  1. Perform benchmarking<\/strong> \u2013 Acquire the knowledge essential to asset management; you don\u2019t know what you don\u2019t know. Evaluate new\/innovative ideas to see if they might add value to corporate goals\/objectives.<\/li>\n
  2. Identify the endgame<\/strong>\u00a0\u2013 Create a policy statement that converts the mission\/vision into an\u00a0Asset Management Plan<\/strong> that establishes SLA requirements and tracks condition. Create a CMMS Utilization Plan<\/strong> that describes how the software will support asset reliability, work force productivity, and job safety. Then, create a Long Range Plan<\/strong> which pursues continuous improvement and identifies the shortest path to value.<\/li>\n
  3. Select a CMMS which is\u00a0<\/strong>configurable<\/strong><\/a> \u2013 The odds are great that you will need to configure your CMMS to support advanced processes, such as adding failure mode to work order, storing results of RCM analysis inside CMMS, and creating the failure analytic. Becoming a reliability leader is a journey which lasts a long time.<\/li>\n
  4. Identify the location hierarchy and asset registry <\/strong>\u2013 Apply a risk-based, criticality to all assets. Capture asset condition, useful life, replacement cost, install date, manufacturer, warranty expiry data, and nameplate data. Link to operating location and system.<\/li>\n
  5. Establish a Reliability Team <\/strong>\u2013 Encourage asset management stakeholders to become certified reliability leaders (i.e. CRL by ReliabilityWeb) so they all speak the same language. This team will manage RCA, chronic failures, defect elimination, and review significant feedback. This team will leverage data<\/strong><\/a> in the CMMS to manage by exception.<\/li>\n
  6. Conduct maintenance needs assessment<\/strong> \u2013 This could be a combination of RCM\/FMEA analysis, PM optimization, OEM guidelines, and senior staff input. Identify optimum maintenance strategies including condition-based technology and wireless sensors.<\/li>\n
  7. Set up job plans and PMs<\/strong> \u2013 These should store job instructions (what to do), craft requirements, materials, tools, hazard precautions, and permit requirements. Also, link job plans to PM.<\/li>\n
  8. Implement closed-loop processes<\/strong><\/a> to support continuous improvement:\n
      \n
    1. Work order feedback<\/strong> \u2013 Examples include maintainability, ergonomic issues, design flaws, safety issues, and inadequate PM-job plan instructions or frequency<\/li>\n
    2. Defect elimination<\/strong> \u2013 Cross functional teams proactively look for defects on critical systems on a regular basis, and make corrections<\/li>\n
    3. Root cause analysis<\/strong> (RCA) \u2013 Significant events require in depth study to prevent recurrence<\/li>\n
    4. Chronic failure analysis<\/strong> \u2013 The reliability team runs an asset offender report to identify bad actors and drills down on failure modes<\/li>\n<\/ol>\n<\/li>\n
    5. Set up formal planning\/scheduling process <\/strong>\u2013 Implement a risk-based work prioritization scheme. Apply ranking to both planning and scheduling backlog. Also, develop integrated project tracking which includes a WBS to store budgets, work orders to capture actuals, and schedule activities to capture progress.<\/li>\n
    6. Conduct audits and surveys<\/strong> for data and processes \u2013 The more advanced a system is, the more likely \u201cthings can go wrong\u201d \u2013 especially data quality. If the goal is to make data-based decisions by leveraging data in the CMMS, then multiple techniques need to be deployed to ensure data quality, such as:\n
        \n
      1. Train staff not only on software navigation but also business rules and definitions<\/strong>. For example, is it clear what defines an asset? A weekly schedule? Reactive maintenance? Maintenance backlog?<\/li>\n
      2. Train operators on identifying failure modes <\/strong>and implement operator driven reliability philosophy.<\/li>\n
      3. Train working level on precision maintenance.<\/strong><\/li>\n
      4. Install a CMMS gatekeeper<\/strong> role to perform work order quality grading. Also, apply consistent categorization\/prioritization.<\/li>\n
      5. Utilize Business Analyst<\/strong> user community surveys. Also, perform process\/procedure audits.<\/li>\n
      6. Proactive error checks<\/strong>, such as, INPRG work with \u201cold actuals”: time in status report, PM-WOs that have been routinely cancelled\/skipped, foundation data missing key attributes, assets with no maintenance strategy, track stockouts, critical spares, and slow-moving inventory.<\/li>\n
      7. Encourage staff feedback<\/strong>. Imagine the benefit of on-going feedback by maintainers, operators, and even engineers to continuously refine maintenance strategies. Communication of this type makes the difference between average and best-in-class.<\/li>\n
      8. Make it easy to capture\/enter missing data<\/strong> elements such as failed component or asset. As far as “ease of use,” strongly consider mobile\/handheld solutions.<\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

        In Summary<\/h2>\n

        The above 10 steps will move any organization from an implement\/operate mode to a utilization\/optimization mindset. And with a long rang plan in hand, organizations can take a step-by-step approach and be assured they are on the right path.<\/p>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

        What is RCM? Reliability centered maintenance (RCM) is a study in how to balance requirements using risk-ranking, optimized maintenance strategies, and focusing on worst offenders. RCM analysis is a review process to preserve a system\u2019s function by identifying likely failure modes and assigning feasible proactive tasks. This overall strategy helps stakeholders work on the right […]<\/p>\n","protected":false},"author":3,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[39],"tags":[],"class_list":["post-7224","post","type-post","status-publish","format-standard","hentry","category-insight"],"acf":[],"yoast_head":"\nWhat is Reliability Centered Maintenance (RCM) and How Do You Get There? - Arora Engineers<\/title>\n<meta name=\"description\" content=\"What is Reliability Centered Maintenance (RCM) and How Do You Get There? \u2013 What is RCM? 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