RCM
RCM
RCM
Management (PGS-MQM-611)
MSc. Sustainable Energy
Reliability Centred
Maintenance
Background
The power industry worldwide has been the subject of
major reviews and reforms in recent years, which have
resulted in changing demands in respect of enhanced
safety, reliability, environmental safeguards and
commercial competition. In such an environment it is
essential that the personnel and the plant and equipment
involved, perform to their optimum levels of capability.
Reliability Centred Maintenance is a maintenance
Optimization tool which has a role in providing an
effective response to such demands on the industry, by
enhancing the effectiveness of operations and
maintenance programmes.
Background
Previously, preventive maintenance was primarily
time-based (e.g., overhauling equipment after a certain
number of hours of flying time). In contrast RCM is
condition-based, with maintenance intervals based on
actual equipment criticality and performance data.
After adopting this approach, airlines found that
maintenance costs remained about constant, but that
the availability and reliability of their aircraft improved
because effort was spent on maintenance of
equipment most likely to cause serious problems. As a
result, RCM is now used by most of the world's
airlines.
Maintenance and Reliability Centred Maintenance
(RCM)
The relationship between RCM and traditional
maintenance practices can best be summarised as
follows: “Plant and equipment are installed and
employed to do what the users want them to do.
Maintenance is undertaken in a variety of forms,
to ensure that the plant and equipment continues
to do what the users want it to do. Reliability
Centred Maintenance determines what
maintenance needs to be performed and what
testing and inspection needs to be performed to
support the maintenance strategy”.
Reliability-centred maintenance
TPM comprises
A philosophy to permeate throughout an
operating company touching people on all levels.
A collection of techniques and practices aimed at
maximizing the effectiveness (best possible
return) of business facilities and processes.
TPM
TPM is a Japanese approach aimed to:
Create a company culture that will give maximum
efficiency
Prevent losses with minimum efforts and cost
• i.e., zero breakdowns and failures, zero
accidents, and zero defects
Create team work (small group activity) focused
on condition and performance to achieve zero
loss
Involve all employees from top management to
operators
TPM
Six major losses
Availability losses
Equipment failure (breakdown) losses
Setup and adjustment losses
Performance (speed) losses
Idling and minor stoppages
(≤10minutes)
Reduced speed losses
Quality losses
Defects is process and reworking losses
Yield losses
Overall equipment effectiveness
The overall equipment effectiveness (OEE) is determined
by the six major losses. The time concepts used are
illustrated in the table below.
Gross available time: t
Available time: tO
Net available time: tR
Operating time: tF Planned
downtime
Net operating time: tN Setup, (vacation,
Valuable Rejects, Breakdowns, adjustments, holidays,
operating nonquality and machine lubrication, changeover
time: tU Speed losses failures and testing time)
Overall equipment effectiveness
The factors used to determine the OEE are
Operational availability AO = tF/tR
Performance rate RP = tN/tF
Quality rate RQ = tU/tF
The quality rate RQ may alternatively be measured as
• Availability:
The probability that an item will be operational at a given time
Remark: Mathematically the Availability of an item is a
measure of the fraction of time that the item is in operating
conditions in relation to total or calendar time
Maintainability
• Maintainability:
The probability that a given active maintenance action, for an item
under given conditions of use can be carried out within a stated
time interval when the maintenance is performed under stated
conditions and using stated procedures and resources (IEC
60050)1)
Remark: probabilistic definition
• Safety:
Freedom from unacceptable risk of harm
Remark: very vague definition
• RAMS: An acronym meaning a combination of Reliability,
Availability, Maintainability and Safety
Dependability
Reliability Availability
Dependability
Maintainability Safety
Terms
• Hazard: A physical situation with a potential for
human injury, damage to property, damage to the
environment or some combination of these
• Individual Risk: The frequency at which an individual
may be expected to sustain a given level of harm from
the realisation of specified hazards
• Social Risk: The frequency with which a specified
number of people in a given population, or population
as a whole, sustain a specified level of harm from the
realisation of specified hazards
Calculations
MTBF = 80 MTBF = 80
RS = Ri n
= 1/80 = 0,0125 = 1/80 = 0,0125 Serial System
R = 0,9 R = 0,9
We know
R(t) = e – . t = – Q(t)
Q(t) = 1 – R(t) Qav ~ . t / 2
= 1 / MTBF [h-1]
MTBF = Operational Time / Number of Stops
MTTR = Sum of Repair Time / Number of Repairs
For the System we yield:
S = = 0.0125 + 0.0125 = 0.025 1/h
MTBFS = 1/(1/MTBF + 1/MTBF) =1/(1/80 + 1/80) = 40 h
RS = R x R = 0,9 x 0,9 = 0,81
QS = Q + Q – (Q x Q) = 0.1 + 0,. – 0.01 = 0.19 = 1 - 0,81
System Reliability
• Most products are made up of a number of components
• The reliability of each component and the configuration of the
system consisting of these components determines the system
reliability (i.e., the reliability of the product).
• The components may be in
– series: system operates if all components operate
– parallel: system operates is any component operates
– combination of series and parallel
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Components in Series
• If the components are in series, the system operates
if all the components operate
• If there are n components in series, where the
reliability if the i-th component is denoted by ri , the
system reliability is
Rs ( r1 )(r2 )( rn )
A B C
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Components in Series
Example 6 A module of a satellite monitoring system
has 500 components in series. The reliability of each
component is 0.999. Find the reliability of the
module. If the number of components is reduced
to 200, what is the reliability?
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Components in Parallel
• If the components are in
parallel, the system A
operates if any
component operates
• If there are n
components in parallel, B
where the reliability of
the i-th component is
denoted by ri , the system
reliability is C
Rp 1 (1 r1 )(1 r2 )(1 rn )
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Components in Parallel
Example 7 Find the reliability of a system with three
components, A, B, and C in parallel. The reliabilities
of A, B, and C are 0.95, 0.92, and 0.90, respectively.
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Redundant Systems and
Backup Components
• If a system contains a
backup or spare components, Power
Source
it can be treated as the one
with components in parallel.
The following formula
is equivalent to
Battery
Rb r1 rb (1 r1 )
R p 1 (1 r1 )(1 rb )
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Combination System
Example 8 Find the reliability of the following system
0.89
0.89 0.95
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FMEA, FMECA, and CBM
It is often wrongly believed that Reliability Centred
Maintenance (RCM), Failure Modes and Effects
Analysis, (FMEA), Failure Modes, Effects, and Criticality
Analysis (FMECA) and Condition Based Maintenance
(CBM) are independent processes.
They‟re not.
RCM Process
As shown below, the four steps of the RCM process
produce a FMEA.
Generation of FMECA
So, when you do RCM, the requirement for a FMEA
and a FMECA is largely satisfied.
RCM Process
FMEA, FMECA, and CBM…when you do RCM, you
do „them all. And don‟t let anyone else tell you
differently
Reliability Centred Maintenance