1 AMG2CC Conference RCM to CBM from Platform To Enterprise 25 February 2015 25 February 2015 Bob Walter Applied Enterprise Systems Department Head [email protected].

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AMG2CC ConferenceRCM to CBM from Platform To

Enterprise

25 February 2015

Bob WalterApplied Enterprise Systems

Department [email protected](814) 863-8876

Jeff BanksComplex System Monitoring

Department [email protected](814) 863-3859

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“…maintains a special long-term strategic relationship with DoD for technology development and engineering applications.”

Established in 1945 by the Navy post WW II Technology Areas

Undersea Weapons Comms and Information

Undersea Vehicles Power and Energy

Hydrodynamics and Structures Navigation

Acoustics & Quieting Materials/ Manufacture S&T

Largest Interdisciplinary Research Unit at Penn State – 1205 faculty/engineers, staff, students

Classified facilities and programs Designated an University Affiliated Research

Center by DoD in 1996

• • • •

• • • •

University Affiliated Research Center (UARC)

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Serve as a university center of research excellence and advanced capabilities for critical DoD sciences and technology and related applications.

Champion the transition of advanced technology to operational systems in support of DoD acquisition programs, legacy platforms and the defense industry.

Contribute to the education, research, and service mission of The Pennsylvania State University

VIRGINIA CLASS

STUDENT PHOTOSTUDENT PHOTO

ARL Penn State Mission

ARMORED AND TACTICAL VEHICLES

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Prototype Systems

RCM Analysis & CBM+ Technologies

U.S. Army Ground Combat Systems

U.S. Army Tactical Wheeled Vehicles

U.S. Marine Corps Motor Transport

and LAV

U.S. Navy Surface Fleet

U.S. Navy Submarines

Trusted Agent Support

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TACOM CBM+ Fleet Management Dashboard

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MaintenanceHistory

Vehicle Sensor and Health

Operational History

OilAnalysis

Vehicle Serial No.

Location

Unit

Family

Fleet

Web-based, Fleet Management application enabling reporting,

searching, filtering, data downloading across multiple data sources.

https://isg.vencore.com/TACOM/Developed by VENCORE for the U.S. Army:

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Maintenance Management CBM+ Example

https://army-cbmplus.sil.arl.psu.edu/StrykerPortal/

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History of Maintenance Methodologies

Ref: Handbook – "Operating Equipment Asset Management – Your 21st Century Competitive Necessity" First Edition

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Reactive Maintenance

• Reactive Maintenance is corrective action applied on failure or obvious, unanticipated threat of failure: run-to-failure.

– Run-to-failure is simplistic, requires no forethought, and, at least up to the point of equipment failure, appears to require the least support.

• An unexpected failure can endanger personnel; releases toxic, flammable or polluting material; interrupts production; and/or causes collateral damage.

• Reactive maintenance does make economic sense in some cases (replacing easily accessible light bulbs, fuses) but the decision to implement reactive maintenance must be based on probability, cost, and consequences.

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Preventive Maintenance (PM)

• Preventative Maintenance tasks include inspection, service and/or replacement conducted at regular, scheduled intervals.– Established to avoid failure

based on average statistical/anticipated lifetime.

• PM may be invasive, requiring an outage and disassembly for visual inspection and/or overhaul/replacement regardless of condition.– The intervals between

specific Preventive Maintenance tasks are based on average life.

• A PM program can be cost effective when equipment operation is consistent, average life is predictable within a reasonable span, failures are well understood, and useful failure statistics are available.

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Preventative Maintenance Checks and Services (PMCS)

• PMCS is  a structured method of maintaining a piece of equipment in a fully mission capable condition so that it is mission ready when needed.

• Designated Intervals. PMCS is conducted at specific time throughout your use of the equipment.  The following intervals are specified for PMCS under normal conditions:

– BEFORE checks and services of PREVENTIVE MAINTENANCE must be performed prior to placing vehicle or its components in operation.

– DURING checks and services of PREVENTIVE MAINTENANCE must be performed while the vehicle and/or its components/systems are in operation.

– AFTER checks and services of PREVENTIVE MAINTENANCE are performed upon completion of mission.

– WEEKLY checks and services of PREVENTIVE MAINTENANCE are performed once every 7 days.

– MONTHLY checks and services of PREVENTIVE MAINTENANCE are performed once every 30 days.

http://www.ut.ngb.army.mil/141mi/Warrior%20Webpages/Driver%27s%20Training/Lesson%205.htm

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Preventative Maintenance: Assumptions

• Correlation between age and/or usage and failure rate.

Increased Age or Usage = Increased Probability of Failure?

• For many systems and components this assumption is not valid.

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Predictive (PdM) or Condition Based Maintenance (CBM)

• PdM/CBM: Maintenance action based on actual condition obtained from in-situ, non-invasive tests, operating and condition measurements.– Condition Based Maintenance has proven capable of identifying

faults early enough to minimize the impact of: • operational interruptions • avoid expensive failures • including collateral damage • significantly reduce the cost of maintenance

• Some potential failures, such as fatigue, are not easily detected with condition measurements.

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Condition Based Maintenance

1. Condition measurement consists of non-invasive measurements that define mechanical and operating condition

– Measurements may be made continuously (on-line) from installed transducers or periodically with portable equipment.

2. Condition monitoring and (health) assessment is the individual and collective comparison of condition measurements, value versus time trends to arrive at an appraisal of current condition, identify and analyze defects (diagnostics).

– Condition assessment is also directed at detecting and identifying degradation mechanisms.

3. Repair and Maintenance actions based on condition monitoring and health assessment—the objective evidence of need.

OPERATING EQUIPMENT ASSET MANAGEMENT YOUR 21ST CENTURY COMPETITIVE NECESSITY, By John S. Mitchell

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P-F Interval

“The interval between the occurrence of a potential failure and its decay into a functional failure”

Reliability-centred Maintenace , by John Moubray

Point where failure starts to occur

Vibration Analysis Detection

Oil Analysis Detection

Audible Noise Detection

Temperature Detection

Con

ditio

n

Time Functional Failure

If the P-F interval is too short,PT&I technology may not be effective.

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CBM Terminology

• Diagnostic Capability: the ability to detect and isolate a failure to a specific platform component or system.

• Predictive Capability: the ability to detect and isolate a fault to a specific platform component or system while the system is still functional.

• Prognostic Capability: the ability to detect and isolate a fault to a specific platform component or system while the system is still functional and the ability to determine the remaining useful life (RUL) until failure.

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Comprehensive Maintenance

• Practitioners recognize that a comprehensive equipment management strategy will include a blend of:– Reactive Maintenance– Preventive Maintenance– Condition-Based

Maintenance

to be applied based on the specific circumstances, probability, and consequences (risk) of failure.

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The RCM Process

• How to best design a maintenance management strategy for your assets or platforms?

– Which methodologies will allow for the most effective and efficient operation and maintenance of each asset.

• The Reliability Centered Maintenance process is used to determine which type or combination of maintenance methodologies is most appropriate and effective for operating a highly reliable and productive assets and platforms.

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The Major Elements of the Basic RCM Process

•RCM Establishment and Planning

•Analysis: – Define the function and functional failures of a

specific platform, system or component.– Then conduct a Failure Modes and Effects

Analysis– Identify the failure consequences– Determine maintenance tasks and intervals.

•Analysis Audit

•Implementation

•Sustaining the RCM Program: – RCM is a ‘Living Program’ – Implement a RCM management, training,

benchmarking, and review process to provide feedback and measurement of progress toward asset management goals

SAE JA1011/1012 and TACOM ILSC CBM+, Reliability Centered Maintenance Process Overview

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Steps for the RCM Analysis Process: Information and Decision

1. Identify System Functions: What does the user need the system to do in its current operating context?

2. Identify Functional Failures: In what way can the system fail (or fail to fulfill its function)?

3. Identify the Failure Modes: What causes the failures?

4. Identify the Failure Effects: What happens when failures occur and what are the symptoms of failure?

5. Identify Failure Consequences: How and why does the failure matter.

• Frequency of occurrence

• Severity of the failure mode

6. Determine Maintenance Tasks and Intervals: Can the failure be predicted or prevented?

7. Identify Other Logical Actions: What can be done if the failure cannot be predicted or prevented?

Reference: SAE JA1011/1012 and TACOM ILSC CBM+, Reliability Centered Maintenance Process Overview

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Platform Degrader Analysis: RCM/CBM/BCA

• The first fundamental concept is that it may not be cost effective to implement health management technology for the entire platform, so where should it be implemented?

• In general, embedded

diagnostic and predictive technologies can have the greatest impact on reducing maintenance activities and increasing platform operational availability when it meets three requirements:

– Relatively high failure rates – Significant maintainability issues – Highly critical components

Maintainability:Identify Critical

Components with Fault Detection/

Isolation Challenges

Reliability: Identify Critical Components

with High Failure Rates and Costs

Identify High Probability of Occurrence Failure Modes of Critical Components

Identify Sensors, Monitoring Hardware and Processes to Enable Diagnostic and/or Predictive

Capabilities

Develop Cost Benefit Analysis Model using Degrader Results to Identify Most Cost Effective

Health Management Design

Logistic: Identify Critical

Components with Significant Logistic Delay and Repair

Times

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Platform Degrader Data Sources

1. Vehicle Part Replacement Data

2. Maintainer Interviews

3. OEM Questionnaire

• Provides a statistical based assessment of

component failure rate.

• Provides an indication of maintainability and

troubleshooting issues.

• Provides insight into

existing system capability and

criticality.

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Platform Degrader Analysis – Systems for Focus

• The results of the degrader analysis include a list of components and sub-systems that contribute most to maintainability, reliability and vehicle operational availability issues.

• When a component or sub-system ranked significantly high in each of

the three data sources, then it was considered a top vehicle degrader.

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Platform Degrader – Potential VHMS Solutions

• This phase of the analysis involves identifying failure modes and sensors that could be utilized to enable a diagnostic and predictive capability for each degrader system or component

• This analysis provides a recommended list of sensors that either

currently exist on the platform or would need to be added to monitor for each identified failure mode.

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Platform Degrader Potential Solutions

• For this fuel system, it was determined based on the criticality portion of the analysis that three of the eleven could be considered ‘high criticality’ failure modes that are candidates for CBM.– Critical: PT Fuel Pump, In-Tank fuel Pumps Non-Critical: Fuel Filter

• The health coverage column provides an approximate indication of the percentage of the failure modes/mechanisms that each VHMS capability could detect.

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CBA Trade Study Model

RCM/Degrader Analysis• Components and Systems• Failure Modes• Quantity/Type of Sensors• Diagnostic Capability• Predictive Capability

Health Management Design Configurator• Generates every possible combination of

design options described by the degrader analysis

Cost Model• On-platform HW/SW• Off-Platform Enterprise Architecture• Publications/Training

Benefit ModelMonetary Benefits• Reduced parts due to decreased misdiagnosisNon-Monetary Benefits • Increase in operational availability T

rade

Spa

ce P

opul

ated

with

Eve

ry D

esig

n C

onfig

urat

ion

ROI, B/C Ratio

Acquisition and Sustainment Costs

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Decision Phase: CBA Trade Study Analysis

• The final phase of the analysis involves evaluating the results from the CBA trade study model for decision making.

• The tool provides the ability to vary the axis combinations: Ao, Cost and HMS level

• Each object is one platform implementation option.

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Ao & ROI & Total Cost Reduction & Acquisition Pareto

2 & 3: Optimized VHMS for ROI and Ao

1:Optimized VHMS for ROI

4: Optimized VHMS for Ao

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Business Case Analysis:Decision Metrics by Subsystem

The intention of this chart is to show the relative benefit for the implementation of CBM solutions for non-electronic LRU’s and the fact that every system should not have CBM implemented.

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Summary – RCM and CBM

• RCM is an effective process and tool for determining the optimum combination of maintenance types for your facility:– Reactive, Preventative, CBM and Proactive

• When it is decided that condition based maintenance (CBM) is the most appropriate and effective form of maintenance for specific equipment then:– Need to determine which PT&I tools will provide the

best indication of a fault within the system.