Living RCM Certified® course

Summary

1 Maintenance decisions – basic problem statement

1. When to maintain? (7:20)
   1. The basic problem
   2. Reliability attributes
   3. Can the probability distribution be known exactly?
   4. Wide versus narrow distribution
   5. Adding a dimension
   6. Formal definition of CBM
   7. Decision factors: probability of failure and severity of consequences
   8. Conclusion
2. Asset maintenance history tracking (23:06)
   1. Descriptive
   2. Quantitative

2 Initial RCM

1. Introduction

   (Part 1 35:57, Part 2 49:40)

   1. The definition of RCM
   2. The historical need for RCM
      1. Expanding expectations of Maintenance
      2. New understanding of asset failure behavior
      3. New maintenance technology
   3. Structured approach to maintenance
      1. Desired performance
      2. The 7 question backbone of RCM
      3. Operating context
   4. Living RCM

2. Functional analysis

   (44:49)

   1. The foundation of RCM
   2. The seven RCM questions
   3. The objective of maintenance
   4. The function statement
   5. Primary and secondary functions
   6. HSE regulations
   7. Performance standards
   8. Protective functions
   9. The functional analysis process
   10. Operating Phases

3. Failures, Failure modes, Effects

   (47:49)

   1. RCM Question 2 – Functional Failures
      1. Total versus partial failure
      2. Competing standards
   2. RCM Question 3 – Failure Modes
      1. Failure mode syntax
      2. How deep and how many?
      3. The “due to” clause
      4. Human Error
   3. RCM Question 4 “Failure Effects
      1. Repair action
      2. The effects narrative

4. Failure consequences

   (37:39)

   1. RCM Question 5 – Why does it matter?
   2. The economics of failure and prevention
   3. Hidden Consequences
   4. Tolerable risk
   5. Economic risk
   6. Health, Safety, and Environmental (HSE) consequences.
   7. Criticality analysis

5. Failure Management Policies

   (51:39)

   1. RCM Questions 6 and 7: Failure management policies
   2. Line of sight
   3. Time based maintenance (TBM)
   4. The “RCM Curves”
   5. How to draw the curves
   6. How to determine the “useful” life
   7. Condition based (predictive) maintenance
   8. Probability and severity
   9. FFI – Failure finding interval
   10. Selecting a default option
   11. No scheduled maintenance

6. Workshop – Initial RCM

   (30:23)

   1. Workshop scope
      1. The Mesh LRCM cloud application
      2. Shovel fleet
      3. Components of the hydraulic system
      4. Hydraulic system required functions and standards
   2. Part I
      1. Functional analysis (Q 1)
   3. Part II
      1. Failure analysis (Q 2)
      2. Failure mode analysis (Q 3)
      3. Effects, Consequences, Mitigation and default actions (Q 4-7)
   4. Part III
      1. RCM Dashboards
         1. RCM progress
         2. Failure Mode detail
         3. Mitigation task detail
         4. Criticality analysis
         5. Knowledge management

3 Living RCM Certified®

1. Part 1 – The nature of data (10:58)
2. Part 2 Living RCM (18:42)

1. 1. LRCM defined
   2. LRCM objectives
   3. The LRCM process
   4. LRCM Workshop
      1. Selecting a failure mode that has been anticipated in RCM analysis
      2. The failure mode’s ending event type
      3. Distinguishing between a suspensions and a potential failure
      4. Failure mode has not been anticipated in the knowledge base
      5. Knowledge Feedback management

4 Reliability analysis

1. Reliability analysis in 2 dimensions

   1. Reliability analysis and decision optimization (25:25)
   2. Sample generation (5:38)

2. Workshop – Weibull analysis and PM Optimization

   (11:17)

   1. Weibull analysis exercises
      1. Engine
      2. Clutch assembly failures
      3.  Clutch event data
      4. Starter motor example that includes suspensions
   2. Optimal maintenance strategies
      1. Age preventive replacement policy
      2. Spares requirement calculation
      3. Interval preventive replacement policy
      4. Deterministic replacement policy

3. Reliability analysis in > 2 dimensions

   1. CBM concepts (11:42)
      1. Deciding on CBM
      2. The classic CBM P-F model
      3. Estimating the P-F interval
      4. An alternative to the P-F model
      5. Predictive maintenance effectiveness
   2. Building a CBM model (25:41)
   3. Deploying the CBM model (6:53)
   4. Continuous CBM decision improvement (13:10)
   5. Sensitivity Analysis (3:07)
   6. Complex items and data preparation (33:28)

4. RAM analysis

   (20:11)

   1. RAM Purpose
   2. RAM technique – Monte Carlo Simulation (MCS)
   3. “Simulating” a single mission of 10000 hours
      1. Averaging the results of many simulation runs
   4. RAM example – a complex system
   5. A second complex system
   6. Conclusion

5. Root Cause analysis (RCA)

   1. RCA –purpose and definitions (NASA)
   2. Undesired outcomes, Events, Conditions, and Barriers
   3. Proximate causes, Root causes, Intermediate causes
   4. Organizational factors
   5. Contributing factor
   6. RCA activities
   7. Accident investigation
   8. RCA tools

© 2016 – 2021, Murray Wiseman. All rights reserved.