UNIT II RCM PROCESS Module 2 PLANNING AND PREPARATION " Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

UNIT IIUNIT II

RCM PROCESSRCM PROCESSRCM PROCESSRCM PROCESS

Module 2Module 2

PLANNING AND PLANNING AND PREPARATIONPREPARATION


"Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

IntroductioIntroductionn


• IntroductionIntroduction• IntroductionIntroduction

• RCM Planning and PreparationsRCM Planning and Preparations• RCM Planning and PreparationsRCM Planning and Preparations

• Review and SummaryReview and Summary• Review and SummaryReview and Summary



Module Preview:Module Preview:Module Preview:Module Preview:

Module Objective:Module Objective:Module Objective:Module Objective: IntroductioIntroductionn


This module provides an overview of This module provides an overview of the elements that must be addressed the elements that must be addressed prior to beginning an RCM analysis prior to beginning an RCM analysis and how those issues affect the and how those issues affect the analysis. analysis.



1. Identify Team and responsibilities 4. Identify and document Review Process2. Identify analysis items 5. Orientation/Training3. Prioritize Items 6. Ground Rules and Assumptions

PLANNING AND PREPARATION

ANALYSIS

RCM ProcessRCM ProcessRCM ProcessRCM Process

AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan

AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan

MaintenanceMaintenanceRequirementsRequirements

MaintenanceMaintenanceRequirementsRequirements

Maintenance Maintenance ProgramProgram

Maintenance Maintenance ProgramProgram

DataDataDataData

1. Equipment Kick-off Meeting2. Initial Data Gathering3. Hardware Partition4. Function5. Functional Failure6. Failure Mode7. Failure Effects8. Failure Consequences9. Task Evaluation10. Task Selection

1. Package Maintenance Task2. Implement Other Actions

SAE JA-

1011

ResultsResults

IMPLEMENT RESULTS

1. Emergent Issues2. Age Exploration3. Hardware Changes4. Trend/degrader analysis5. Document Reviews

SUSTAIN

FMECA

Planning and Planning and PrepPrep


1.1. Identify the RCM Team and Identify the RCM Team and responsibilitiesresponsibilities

2.2. Identify the Items subject to AnalysisIdentify the Items subject to Analysis

3.3. Prioritize Analysis ItemsPrioritize Analysis Items

4.4. Identify and document the analysis Identify and document the analysis review and approval processreview and approval process

5.5. Project Orientation Brief/TrainingProject Orientation Brief/Training

6.6. Develop Analysis Ground Rules & Develop Analysis Ground Rules & AssumptionsAssumptions

Steps:Steps:Steps:Steps: Planning and Planning and PrepPrep




Step 1: Identify the RCM Team and responsibilitiesStep 1: Identify the RCM Team and responsibilities• Team compositionTeam composition

OperatorsOperators MaintainersMaintainers Engineering/Logistics/Safety/SMEEngineering/Logistics/Safety/SME Data Managers/AnalystsData Managers/Analysts RCM Analysts (may be one or more of above or RCM Analysts (may be one or more of above or

separate)separate) Project Manager/RCM Implementation Project Manager/RCM Implementation

Manager/Facilitator (one of above or separate)Manager/Facilitator (one of above or separate)• ResponsibilitiesResponsibilities

Support roles (subject matter expertise)Support roles (subject matter expertise) Analysis and documentationAnalysis and documentation Data collection Data collection Review and approvalReview and approval Implementation Implementation

• Team Availability and InterfaceTeam Availability and Interface• Analysis structure (facilitated group or assigned Analysis structure (facilitated group or assigned

analyst)analyst)

Step1:Step1:Step1:Step1: Planning and Planning and PrepPrep




Step 2: Identify Analysis ItemsStep 2: Identify Analysis Items• List the upper level item or items that will be analyzedList the upper level item or items that will be analyzed• May be an entire asset or a list of equipment/systemsMay be an entire asset or a list of equipment/systems• Include boundaries if necessaryInclude boundaries if necessary• Be specific Be specific

Examples of analysis items:Examples of analysis items:• E-6 aircraftE-6 aircraft• Sea-wolf SubmarineSea-wolf Submarine• Plant water supply System (including well, pumps, Plant water supply System (including well, pumps,

and piping up to main shut-off valve)and piping up to main shut-off valve)• Water-jet cutting machine and Milling MachineWater-jet cutting machine and Milling Machine• Soot Blowing System, Absorber Tower System, and Soot Blowing System, Absorber Tower System, and

Boiler Air and Gas System Boiler Air and Gas System

Step 2:Step 2:Step 2:Step 2: Planning and Planning and PrepPrep




Step 3: Prioritize Analysis Items (Analysis scope)Step 3: Prioritize Analysis Items (Analysis scope) List the preferred order that upper level assets List the preferred order that upper level assets

will undergo analysiswill undergo analysis Does not mean one item must be completed Does not mean one item must be completed

before another startsbefore another starts In the case of complex items such as an entire In the case of complex items such as an entire

aircraft or major system, additional prioritization aircraft or major system, additional prioritization may be needed after hardware partitioningmay be needed after hardware partitioning





Step 4: Identify and Document the Review and Step 4: Identify and Document the Review and Approval Process Approval Process

• Who is responsible for review and approval of Who is responsible for review and approval of each analysiseach analysis

• Are reviews informal or formal, group or Are reviews informal or formal, group or individualindividual

• Review/Approval should include senior RCM Review/Approval should include senior RCM analyst and system subject matter expertanalyst and system subject matter expert





Step 5: Project Orientation Brief/TrainingStep 5: Project Orientation Brief/Training• Objective is to begin the “buy-in” process and Objective is to begin the “buy-in” process and

remove potential roadblocksremove potential roadblocks• Should include all personnel significantly Should include all personnel significantly

affected by RCM results, including operations affected by RCM results, including operations and management representativesand management representatives

• Should include the following topics:Should include the following topics: Items in step 1-4Items in step 1-4 General RCM process overviewGeneral RCM process overview What’s in it for everyoneWhat’s in it for everyone What’s expected of everyoneWhat’s expected of everyone Statement of management buy-inStatement of management buy-in Statement of key groups (maintenance, Statement of key groups (maintenance,

production) buy-in. (team member advocates)production) buy-in. (team member advocates)• Formal analyst training only required for key Formal analyst training only required for key

participantsparticipants





Step 6: Ground Rules & Assumptions (GR&A)Step 6: Ground Rules & Assumptions (GR&A)• A compilation of information required by RCM A compilation of information required by RCM

analysts to perform analysisanalysts to perform analysis• Items included:Items included:

- Description of operating environment (operating Description of operating environment (operating context) context)

- Standard operating proceduresStandard operating procedures- Data sourcesData sources- Failure mode sourcesFailure mode sources- Analytical methodsAnalytical methods- Cost-benefit analysis methodsCost-benefit analysis methods- Default ValuesDefault Values- Acceptable probability of failureAcceptable probability of failure- Labor ratesLabor rates- Equipment usage ratesEquipment usage rates





RCM Program RCM Program PlanPlan

RCM Program RCM Program PlanPlan



RCM Projects should document the results of the RCM Projects should document the results of the planning and preparation steps into an planning and preparation steps into an RCM RCM Program PlanProgram Plan

• Scope and size of plan is dependent on Scope and size of plan is dependent on projectproject

• Ensures consistency of analysis processEnsures consistency of analysis process• Establishes priorities and scheduleEstablishes priorities and schedule• Documents contributions of team Documents contributions of team

members and concurrence by members and concurrence by management management

• Can be used for funding justification and Can be used for funding justification and to gain management supportto gain management support



RCM Program PlanRCM Program PlanRCM Program PlanRCM Program Plan Planning and Planning and PrepPrep


RCM Program Plan Elements:RCM Program Plan Elements:• Team and Responsibilities (Planning Step 1)Team and Responsibilities (Planning Step 1)• Analysis scope (what and what order: Planning Analysis scope (what and what order: Planning

steps 2 and 3)steps 2 and 3)• Review and approval process (Planning Step 4)Review and approval process (Planning Step 4)• Training Requirements (Planning Step 5 +)Training Requirements (Planning Step 5 +)• Ground Rules and Assumptions (Planning Step Ground Rules and Assumptions (Planning Step

6)6)• Sustaining task proceduresSustaining task procedures• Hazard Risk MatrixHazard Risk Matrix• Metrics and Reporting requirementsMetrics and Reporting requirements• Funding requirementsFunding requirements• Plan of action and milestones Plan of action and milestones • Contractor support requirementsContractor support requirements• DeliverablesDeliverables



Team and Team and ResponsibilitiesResponsibilities




Facilitated approach vs. dedicated Facilitated approach vs. dedicated analystanalyst• Facilitated group approachFacilitated group approach

• Analysis is performed during meetings of key Analysis is performed during meetings of key personnel in presence of a facilitatorpersonnel in presence of a facilitator

• Maximizes buy-in from participantsMaximizes buy-in from participants

• Limited by amount of time key persons can Limited by amount of time key persons can attend meetingsattend meetings

• Focuses on consensus of stakeholders vice Focuses on consensus of stakeholders vice detailed/analytical solutions detailed/analytical solutions







Facilitated approach vs. dedicated Facilitated approach vs. dedicated analystanalyst•Dedicated analystDedicated analyst

• Analysis is performed by dedicated RCM Analysis is performed by dedicated RCM expert(s) using information gathered from expert(s) using information gathered from system experts and other sourcessystem experts and other sources

• Still must include participation of key SMEs Still must include participation of key SMEs (operators/maintainers) for analysis to be (operators/maintainers) for analysis to be effectiveeffective

• Less daily impact on non-RCM analyst Less daily impact on non-RCM analyst participantsparticipants

• Participants don’t need extensive RCM training, Participants don’t need extensive RCM training, just basic orientationjust basic orientation

• More conducive to outside analytical assistance More conducive to outside analytical assistance (outsourcing)(outsourcing)







Facilitated approach vs. dedicated analystFacilitated approach vs. dedicated analyst

Which is best? Which is best?

Depends on desires and resources of each Depends on desires and resources of each organizationorganization



Scope of Scope of Analysis:Analysis:Scope of Scope of Analysis:Analysis:


Planning and Planning and PrepPrepScope May be dependent on:Scope May be dependent on:

• Funding/personnel resources/management Funding/personnel resources/management commitmentcommitment• Pilot project vs. full-scalePilot project vs. full-scale

•Objectives of analysisObjectives of analysis• Fix current “headaches” vs. maintenance optimizationFix current “headaches” vs. maintenance optimization

• ““Age/Remaining planned Life” of analysis items Age/Remaining planned Life” of analysis items • Potential risk vs. returnPotential risk vs. return

• Criticality analysis (Risk Indices) may be used Criticality analysis (Risk Indices) may be used to further prioritize or limit the analysisto further prioritize or limit the analysis

MUST ensure potential safety/environmental MUST ensure potential safety/environmental issuesissues

are not overlooked in less than complete are not overlooked in less than complete analysis!analysis!



RCM TrainingRCM TrainingRCM TrainingRCM Training Planning and Planning and PrepPrep

Planning and Planning and PrepPrepTraining Requirements (Planning Step 5 +)Training Requirements (Planning Step 5 +)

•OrientationOrientation• Provided to significantly affected parties and Provided to significantly affected parties and

participants early in the processparticipants early in the process• Essential in the dedicated analyst approachEssential in the dedicated analyst approach• Typically 2 – 4 hoursTypically 2 – 4 hours

• Analyst training Analyst training •Analyst approach: only required for those key Analyst approach: only required for those key

individuals intimately involved in the analysis individuals intimately involved in the analysis processprocess

• Facilitated approach: typically provided to all Facilitated approach: typically provided to all participantsparticipants

• Typically 3-5 daysTypically 3-5 days

•Management overviewManagement overview• Provided to key management to gain buy-in Provided to key management to gain buy-in

develop agreement on expectationsdevelop agreement on expectations• Typically 1-4 hoursTypically 1-4 hours



Sustaining the RCM Sustaining the RCM Analysis:Analysis:

Sustaining the RCM Sustaining the RCM Analysis:Analysis:

• Defines how the RCM team plans to monitor Defines how the RCM team plans to monitor and improve the effectiveness of the and improve the effectiveness of the maintenance program throughout the life of maintenance program throughout the life of the equipmentthe equipment

• RCM must be maintained over time to realize RCM must be maintained over time to realize its full benefitits full benefit

RCM Sustainment is discussed in more detail in Unit IVRCM Sustainment is discussed in more detail in Unit IV





Review and Review and SummarySummary

Review and Review and SummarySummary

IntroductionIntroduction

– Learning ObjectivesLearning Objectives

Planning and preparationPlanning and preparation

– Required StepsRequired Steps

– RCM PlanRCM Plan

– Provide an overview of the issuesProvide an overview of the issues that must be accomplished prior tothat must be accomplished prior to beginning RCM analysis.beginning RCM analysis.

Module ObjectiveModule Objective



End of Module up next……..

Hardware Partitioning

End of Module up next……..

Hardware Partitioning

UNIT II RCM PROCESS Module 2 PLANNING AND PREPARATION " Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

Documents

rcm analysis

analysis review

analysis itemslist

items subject

rcm team

gas system step

major system

case of complex items