But just what does the term really mean? What issues will make plant management embark on a reliability project?
Definition Reliability centered maintenance RCM is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company or facility. The final result of an RCM program is the implementation of a specific maintenance strategy on each of the assets of the facility.
The maintenance strategies are optimized so that the productivity of the plant is maintained using cost-effective maintenance techniques. There are four principles that are critical for an reliability centered maintenance program.
It is the reliability, rather than the functionality, of these systems that are considered. The seven questions that need to be asked for each asset are: What are the functions and desired performance standards of each asset? How can each asset fail to fulfill its functions?
What are the failure modes for each functional failure? What causes each of the failure modes? What are the consequences of each failure? What should be done if a suitable proactive task cannot be determined?
Want to learn more about key performance indicators KPIs for maintenance excellence? The most critical assets are those that are likely to fail often or have large consequences of failure. With this maintenance strategy, possible failure modes and their consequences are identified; all while the function of the equipment is considered.
Cost-effective maintenance techniques that minimize the possibility of failure can then be determined. The most effective techniques are then adopted to improve the reliability of the facility as a whole.
Additional costs of ownership, like those considered in evidence-based maintenance, are not considered, and are therefore not factored into the maintenance considerations. Define the boundaries and function of the systems that contain the selected equipment The equipment belongs to a system that performs a crucial function.
The system can be large or small, but the function of the system, and its inputs and outputs, should be known. For example, the function of a conveyor belt system is to transport goods. Its inputs are the goods and mechanical energy powering the belt, while its outputs are the goods at the other end.
In this case, the electric motor supplying the mechanical energy would be considered as part of a different system. Define the ways that the system can fail failure modes In step 3 the objective is to list all of the ways that the function of the system can fail.
For example, the conveyor belt may fail by being unable to transport the goods from one end to the other, or perhaps it does not transport the goods quickly enough.
Identify the root causes of the failure modes With the help of operators, experienced technicians, RCM experts and equipment experts, the root causes of each of the failure modes can be identified.
Root causes for failure of the conveyor could include a lack of lubrication on the rollers, a failure of a bearing, or a loosened belt.
Assess the effects of failure In this step, the effects of each failure mode are considered. Equipment failures may affect safety, operations and other equipment. Criticality of each of these failure modes can also be considered.
There are various recommended techniques that are used to give this step a systematic approach. Your answer is the most important failure modes that should be prioritized for further analysis. Importantly, the failure modes that are retained include only those that have a real probability of occurring under realistic operating conditions.Asset Reliability Program is to maximize equipment life and minimize scheduled reliability engineering team may, also, require a redesign.
2. Target specific equipment & processes (80/20 approach): Work management system to correct and track deficiencies Budget requirements. 9. Tracking mechanical reliability. He is a Certified Maintenance and Reliability Professional (CMRP) and a Certified Plant Maintenance Manager (CPMM) and holds an MS in Chemical Engineering and a BS in Chemistry.
David J. Mierau, PE, CMRP, is a global reliability engineering and asset management consultant focused on the pharmaceutical and biotech industries. Triad Unlimited is a Minority Owned, Certified Veteran Owned Small Business (VOSB), dedicated to providing trusted and effective Asset Management solutions to our customers.
Our team is made up of Asset Management practitioners who specialize in developing sustainable solutions customized to fit our clients problem specific need. Reliability centered maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company or facility.
The final result of an RCM program is the implementation of a specific maintenance strategy on each of the assets of the facility. Our Reliability Engineering and Asset Management (MSc) is the only global programme that offers a complete spectrum of education with real industrial applications in the field of plant maintenanceLearning from major failures and near misses as feedback to improve design.
Reliability engineering and asset management is a critical field of managerial and technical importance to both the UK and the international industry.
It is estimated that a significant amount of typical yearly plant cost is spent maintaining that plant.