STAMP
PLACE
Reliability
HERE
Centered
Maintenance
What is RCM ?
A Method for defining
(RCM)
maintenance strategy in Increase your business profit by managing
a coherent, systematic, your plant reliability
and logical manner. It is Comparative Maintenance
a structured Cost
methodology for
A frequently referenced study conducted by
“determining the
EPRI reported lifecycle cost savings for different
maintenance maintenance program, as shown in above figure
requirements of any
physical asset in its This is why managing your maintenance strategy
operating context” is crucial part in your business.
Objective of
RCM ?
1. To improve
operating
performance
2. Greater maintenance
cost effectiveness
3. Longer useful life of Finding Optimum
equipments Balance
4. Comprehensive By using RCM program, you can find the
maintenance right maintenance program within the
database right maintenance frequency, and this
will give you optimum balance to get
the more effective maintenance cost.
Reliability Improvement Processes Through RCM Program
#preparation
Task
Asset Identification
Register
#database
Reliability New database (Continuous
Model improvement)
Criticality
Analysis
FMEA
Maintenance
#default action Cost Optmization
Failure Defense Weibull
Task Analysis
Preventive
Maintenance
Task Execution
#identifying
Condition Based
the right task
Maintenance
Design
improvement /
Overhaul
Our RCM program’s target is shown on picture on the left.
To increase EAF (Total Revenue), with decreasing MOH (Man Outage Hour), FOH (Forced
Outage Hour), POH (Planned Outage Hour), Derating, and Loss in production capability.
Asset Register
What is Asset Register ? Asset Register will help
The number and variety of items means you answer these
that we need to draw up a questions
comprehensive list of these assets and
develope suitable numbering systems
before attempting to asses
maintenance requirement.
How should
How should
the register
asset be
be
numbered ?
What prepared ?
information
should be
recorded ?
Failure Mode
and Effect
Analysis
“How to define functional
(FMEA)
failure to assess failure
effect or consequences”
What is Failure Mode ?
A Failure Mode is any event which
Is the failure mode
causes a functional failure
a random Is the failure mode
Function Functional Failure Failure Mode occurrence or hidden or evident?
(Loss of Function) (Cause of Failure) time/usage related?
1 To transfer water A Unable to transfer 1 Bearing seizes
from tank X to tank any water at all 2 Impeller comes adrift
Y at not less than 3 Impeller jammed by
800 liters/minute foreign object
4 Coupling hub shears due
to fatigue If evident, what is
Motor burns out
Inlet valve jams closed the PF interval?
…etc
B Transfers less than 1 Impeller worn
800 liters per 2 Partially blocked suction
minute line
…etc
Reliability
Model Block
Diagram
“How to define the
probability of failure”
What is it for ?
if FMEA help you to define the effect
of failure,
Reliability Block Diagram would help
you to define probability of failure
Criticality (or
Risk) Analysis
“How to calculate the
risk, so you can manage
the risk carefully”
Criticality or Risk Analysis will
help you answer these questions
What could happen if the failure occured ?
How often the failure occured ?
Is the risk acceptable ?
Reliability #probability
Model Block
Diagram
Criticality
Analysis
FMEA
#impact
Failure
Defense Task “it’s about making a plan
to maintain your
equipment in a strategic
way”
Mostly Failure Defense Task consist of :
Preventive
maintenance task
Scheduled
failure-finding
task (Predictive)
No scheduled
maintenance
(Corrective)
Re-design /
Overhaul
“Using weibull analysis,
you can forecast the time
Weibull of unit/component
Analysis failure, which is an
important information to
improve your
maintenance program”
What is it for ?
To forecast at time of unit failure
To decide frequency of
maintenance action
To ensure that maintenance
action is not too often
To ensure that maintenance
action would act before failed
To optimize maintenance cost
