1 Problem statement

Day 1 8:30 – 9:30

1. When to maintain? (Slides)
   1. The basic problem
   2. Reliability attributes
   3. Wide versus narrow distribution
   4. Add a dimension
   5. Formal definition of CBM

2 Initial RCM

Day 1 9:30 – 12:30 “Introduction”

1. The definition of RCM (slides)
2. The historical need for RCM
   1. Expanding expectations of Maintenance
   2. New understanding of asset failure behavior
   3. Warnings of failure
   4. Failure pattern A
   5. The three epochs of expanding understanding
   6. Life cycle costing
   7. New maintenance technology

    

   10:30 Coffee break

   1. RCM’s structured approach to maintenance
   2. Desired performance graph
   3. The 7 question backbone of RCM
   4. Why make the RCM effort
   5. Operating context
   6. Failure consequences
   7. Maintenance policies
   8. ISO 55000 and “line of sight”
   9. The RCM decision tree.
   10. The RCM guide.
   11. Living RCM
   12. Reliability analysis and samples
   13. Recording failure mode instances for samples

 

Day 1: 1:30 – 4:30 “Functional analysis”

1. The foundation of RCM (slides)
2. The seven RCM questions
3. The objective of maintenance
4. Agenda
5. The function statement
6. The distinction between design capability and required performance
7. Pump performance standard
8. An adequate margin for deterioration
9. Primary and secondary functions
10.  “Your Car” – What are its functions?
11. Space shuttle arm example
12. Primary functions
13. Primary function statement examples?
14. Secondary functions
15. Superfluous functions
16. HSE regulations enforced by a government agency
17. Performance standards
18. Multiple performance standards
19. Quantitative performance standards
20. Qualitative performance standards

3:30 Coffee break

1. Containment – absolute if not quantified.
2. Variation in demand
3. The (upper and lower) performance standard
4. Protective functions
5. Function statements are simple.
6. The functional analysis process
7. Air conditioning pack
8. DC10 AC Pack functional analysis
9. Distributed control system (DCS)
10. Passenger rail car bogey
11.  The operating context

Day 2 8:30 – 12:30 “Failures, Failure Modes, and Effects”

1. Defining a Functional Failure
2. Failures identify the performance loss
3. The general failed state
4. Total versus partial failure
5. Partial failure with multiple performance standards
6. Failure to remain within upper and lower limits
7. Why distinguish between > and <?
8. Different people, different standards
9. Solving the recurring dilemma
10. Functional failures address performance standards.
11. Failed state exercise
12. RCM Question 3 – Failure Modes
13. Warning: Slightly different definitions of “Failure Mode”
14. FMECA (MIL STD 1629A) definitions:
15. The event that causes the failure
16. How much detail (how many failure modes)?
17. The two Failure Mode decisions
18.  “How deep”
19. “How many?”
20. “How deep and how many?”
21. The “due to” clause
22. Three reasons why a performance standard may not be achieved
23. Human Error
24. James Reason – Psychological Human Error
25. RCM includes Human error
26. Operating context
27. Failure Mode Exercise

Failure Effects

1. Knowledge versus skill
2. RCM Question 4 “Failure Effects
3. What is the difference between a Failure Effect and a Failure Consequence?
4. Repair action – part of the Effects description
5. Zero based analysis – Assumptions when describing the Effects
6. What should be described in the Effects?

10:30 Coffee Break

Day 2 1:30 – 2:30 “Failure Consequences”

1. RCM Question 5 – Why does it matter?
2. Four failure consequences.
3. Every decision point on the RCM decision algorithm, actually has two questions:
4. The economics of failure and prevention
5. Hidden Consequences
6. Hidden failures
7. What availability to I want from my protective device?
8. Who decides what is tolerable?
9. Tolerable risk of fatality
10. Probability of being killed on the road or at work
11. Economic risk
12. Reducing the probability of multiple failure
13. Typical hidden functions:
14. Health, Safety, and Environmental (HSE) consequences.
15. RCM decision: Two or more proactive tasks
16. Default tasks
17. What is tolerable?

2:30 Coffee break

Day 2 2:45 – 4:30 Failure Management Policies

1. Questions 6 and 7: The “initial” failure management policy (slides)
2. RCM “prefers” proactive policies
3. Line of sight
4. Time based maintenance (TBM)
5. The “RCM Curves”
6. Explanation of the paradox
7.  What does the astute manager ask?
8. Failure pattern B
9. How to draw the curves
10. Exercise
11. How to get the useful life
12. Condition based (predictive) maintenance
13. When to maintain?
14. The basic problem
15. Add a dimension
16. Formal definition of CBM
17. The CBM decision depends on probability and severity

 The policies FF, NSM, and redesign

1. FFI – Failure finding interval
2. No scheduled maintenance
3. Selecting a default option
4.  The goals of redesign

3 Day 3 8:30 – 12:30 Living RCM – Achieving reliability from data

1. The objectives of LRCM

   1. Objective 1: Work order data quality for RA – the nature of data
   2. Age data
   3. Condition data
   4. Cost data
   5. The key (EAM-RCM) relationship
   6. Data samples for RA
   7. The meaning of “optimal”
   8. Objective 2: Systematic RCM knowledge improvement

2. LRCM procedures and software

   1. Procedures – Continuous improvement in the maintenance process
   2. Procedures – LRCM scheduled activities
   3. Software – MESH LRCM Modules

3. LRCM Workshop

   1. Work order data quality
   2. RCM Knowledge continuous improvement
   3. Processing knowledge feedback

4. Empowerment and recognition

   1. Initial RCM dashboard
   2. Living RCM dashboard

4 Day 3 1:30- 4:30 Reliability analysis – Decision modeling

Micro (day-to-day decision) analysis

1. Reliability Analysis: 2 dimensions (Statistical and probabilistic concepts)
   1. Reliability analysis is counting
   2. CBM “predictive” reliability analysis
   3. The six RCM curves. What do they really mean?
   4. Conditional probability of failure
   5. Conditional failure probability and reliability
   6. What about the failure rate?
   7. Random failure. Is it really “random”?
   8. Conclusion, so what?
2. Weibull Exercises
   1. Perkins marine diesel engine
      1. Problem background
      2. Problem requirements
      3. General data
      4. Event data
      5. Trend analysis
      6. Weibull analysis
      7. Plot the age reliability graphs
   2. Clutch assembly failures
      1. Grouped data
      2. Clutch general data
      3. Clutch event data
      4. Clutch reliability graphs and report
   3. Starter motor example that includes suspensions
      1. General data
      2. Weibull analysis results
3. Optimal maintenance strategies
   1. Age preventive replacement policy
      1. Perkins engine – maintenance and spares optimization requirements
      2. Verify and complete the general data
      3. Age preventive replacement policy
      4. Spares requirement
   2. Interval preventive replacement policy
      1. Perkins engine with interval rather than age replacement
      2. Interval preventive replacement calculation for Perkins engine fleet
      3. Perkins interval replacement policy spares calculation
   3. Deterministic replacement policy
      1. Data input for a deterministic policy
      2. Deterministic policy calculation and results
4. Reliability analysis in > 2 dimensions EXAKT basic tutorial
   1. What will you learn in this tutorial?
   2. Launch EXAKT
   3. Create a database (document) for the model
   4. Connect the model to the age and CBM data
   5. Examine the Inspections table
   6. Examine the Events table
   7. Examine the other tables
   8. Models table
   9. Enter general project data
   10. Combine the Events and Inspections tables into the C_Inspections table
   11. Build a trial model with all four CBM variables
   12. Examine the parameter estimation report.
   13. Build PH model with all significant variables
   14. Eliminate a significant variable
   15. Compare the two models
   16. Reactivate the model to be retained
   17. Goodness of fit
   18. Transition model
   19. Transition probability matrix
   20. Optimal decision policy

Macro (long range) “RAM analysis“

1. RAM Purpose
2. Types of RAM performance predictions
3.  RAM technique – Monte Carlo Simulation (MCS)
   1. “Simulating” a single mission of 10000 hours
   2. Averaging the results of many simulation runs
   3. Summary of the RAM MCS method
   4. A simple first example
   5. Another simple example
   6. RAM example 3 – a complex system
   7. RAM example 4 – a second complex system

Supplemental Day 4-5 “RCM Facilitation”

1. Primary function of the facilitator
2. Secondary functions
   1. Required skill sets
3. Facilitating the RCM Q&A process
   1. Q1 The function statement
   2.  Q2 The failed states address performance requirements
   3.  Q3 – The failure mode
   4. Q3 Which failure modes to include
   5. Q3 The failure mode due to clause
   6. Q3 Failure mode depth and quantity
   7. Q4 Failure Effects – the story
   8. Q4 Failure effects – the sub questions
   9. Q5 – Why does it matter – the consequences of failure
   10. Q6 – The PM tasks – what can be done proactively?
   11. Q6 – The PM task intervals
   12. Q6 – Correctly describing the PM tasks
4. Managing the RCM process
   1. Prepare for the meetings
5. Levels of analysis and boundaries
   1. The advantages of starting high
   2. Other disadvantages of starting too low
   3. Start high then move lower if necessary
   4. Complex components
   5. “Rotable” components
   6. Which failure modes to exclude
   7. Minimum jargon and simplified structure
   8. Recognize absence of sufficient knowledge
   9. Avoid redesign in the meeting
   10. Complete the RCM knowledge base
   11. Prepare the audit file
   12. Lead the RCM sessions
   13. Adhering to schedule
6. Administrating the RCM project
   1. Project parameters
   2. The schedules and plan
   3. Top management presentation
   4. Initiate a living RCM process
   5. Who is going to be the facilitator?

Supplemental Day 5 “Implementing the RCM analysis results”

1. The RCM audit
   1. Choice of auditor
   2. Timing of the audit
   3. Audit both process and substance
   4. Common issues for auditor to watch for:
   5. Functions
   6. Failed states
   7. Failure mode issues
   8. Failure effects detail
   9. Consequences attention points
   10. Task concerns
   11. One-off changes:
   12. Justification
   13. Design, implementation, and follow-up
   14. Managing the one-off change
2. Packaging the RCM tasks
   1. Maintenance schedules
3. Systems and Living RCM
   1. Planning and control
   2. Continuous improvement