{"id":2109,"date":"2012-06-10T09:11:27","date_gmt":"2012-06-10T14:11:27","guid":{"rendered":"http:\/\/www.livingreliability.com\/en\/?p=2109"},"modified":"2025-11-06T05:48:44","modified_gmt":"2025-11-06T10:48:44","slug":"rcm-analyst-course-outline","status":"publish","type":"post","link":"https:\/\/www.livingreliability.com\/en\/posts\/rcm-analyst-course-outline\/","title":{"rendered":"RCM – Analyst course outline"},"content":{"rendered":"

1 Problem statement<\/a><\/h1>\n

Day 1 8:30 – 9:30<\/h2>\n
    \n
  1. When to maintain? (Slides)<\/a>\n
      \n
    1. The basic problem<\/a><\/li>\n
    2. Reliability attributes<\/a><\/li>\n
    3. Wide versus narrow distribution<\/a><\/li>\n
    4. Add a dimension<\/a><\/li>\n
    5. Formal definition of CBM<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

      2 Initial RCM<\/h1>\n

      Day 1 9:30 – 12:30 \u201cIntroduction<\/a>\u201d<\/h2>\n
        \n
      1. The definition of RCM (slides)<\/a><\/li>\n
      2. The historical need for RCM<\/a>\n
          \n
        1. Expanding expectations of Maintenance<\/a><\/li>\n
        2. New understanding of\u00a0asset failure behavior<\/a><\/li>\n
        3. Warnings of failure<\/a><\/li>\n
        4. Failure pattern A<\/a><\/li>\n
        5. The three epochs of expanding understanding<\/a><\/li>\n
        6. Life cycle costing<\/a><\/li>\n
        7. New maintenance technology<\/a><\/li>\n<\/ol>\n

           <\/p>\n

          10:30 Coffee break<\/h3>\n
            \n
          1. RCM\u2019s structured approach to maintenance<\/a><\/li>\n
          2. Desired performance graph<\/a><\/li>\n
          3. The 7 question backbone of RCM<\/a><\/li>\n
          4. Why make the RCM effort<\/a><\/li>\n
          5. Operating context<\/a><\/li>\n
          6. Failure consequences<\/a><\/li>\n
          7. Maintenance policies<\/a><\/li>\n
          8. ISO 55000 and \u201cline of sight\u201d<\/a><\/li>\n
          9. The RCM decision tree.<\/a><\/li>\n
          10. The RCM guide.<\/a><\/li>\n
          11. Living RCM<\/a><\/li>\n
          12. Reliability analysis and samples<\/a><\/li>\n
          13. Recording failure mode instances for samples<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

             <\/p>\n

            Day 1: 1:30 – 4:30 \u201cFunctional analysis<\/a>\u201d<\/h2>\n
              \n
            1. The foundation of RCM (slides)<\/a><\/li>\n
            2. The seven RCM questions<\/a><\/li>\n
            3. The objective of maintenance<\/a><\/li>\n
            4. Agenda<\/a><\/li>\n
            5. The function statement<\/a><\/li>\n
            6. The distinction between design capability and required performance<\/a><\/li>\n
            7. Pump performance standard<\/a><\/li>\n
            8. An adequate margin for deterioration<\/a><\/li>\n
            9. Primary and secondary functions<\/a><\/li>\n
            10. \u00a0\u201cYour Car\u201d \u2013 What are its functions?<\/a><\/li>\n
            11. Space shuttle arm example<\/a><\/li>\n
            12. Primary functions<\/a><\/li>\n
            13. Primary function statement examples?<\/a><\/li>\n
            14. Secondary functions<\/a><\/li>\n
            15. Superfluous functions<\/a><\/li>\n
            16. HSE regulations enforced by a government agency<\/a><\/li>\n
            17. Performance standards<\/a><\/li>\n
            18. Multiple performance standards<\/a><\/li>\n
            19. Quantitative performance standards<\/a><\/li>\n
            20. Qualitative performance standards<\/a><\/li>\n<\/ol>\n

              3:30 Coffee break<\/h3>\n
                \n
              1. Containment \u2013\u00a0absolute\u00a0if not quantified.<\/a><\/li>\n
              2. Variation in demand<\/a><\/li>\n
              3. The (upper and lower) performance standard<\/a><\/li>\n
              4. Protective functions<\/a><\/li>\n
              5. Function statements are simple.<\/a><\/li>\n
              6. The functional analysis process<\/a><\/li>\n
              7. Air conditioning pack<\/a><\/li>\n
              8. DC10 AC Pack functional analysis<\/a><\/li>\n
              9. Distributed control system (DCS)<\/a><\/li>\n
              10. Passenger rail car bogey<\/a><\/li>\n
              11. \u00a0The operating context<\/a><\/li>\n<\/ol>\n

                Day 2 8:30 – 12:30 \u201cFailures, Failure Modes, and Effects<\/a>\u201d<\/h2>\n
                  \n
                1. Defining a Functional Failure<\/a><\/li>\n
                2. Failures identify the performance loss<\/a><\/li>\n
                3. The general failed state<\/a><\/li>\n
                4. Total versus partial failure<\/a><\/li>\n
                5. Partial failure with multiple performance standards<\/a><\/li>\n
                6. Failure to remain within upper and lower limits<\/a><\/li>\n
                7. Why distinguish between > and <?<\/a><\/li>\n
                8. Different people, different standards<\/a><\/li>\n
                9. Solving the recurring dilemma<\/a><\/li>\n
                10. Functional failures address performance standards.<\/a><\/li>\n
                11. Failed state exercise<\/a><\/li>\n
                12. RCM Question 3 \u2013 Failure Modes<\/a><\/li>\n
                13. Warning: Slightly different definitions of \u201cFailure Mode\u201d<\/a><\/li>\n
                14. FMECA (MIL STD 1629A) definitions:<\/a><\/li>\n
                15. The event that causes the failure<\/a><\/li>\n
                16. How much detail (how many failure modes)?<\/a><\/li>\n
                17. The two Failure Mode decisions<\/a><\/li>\n
                18. \u00a0\u201cHow deep\u201d<\/a><\/li>\n
                19. \u201cHow many?\u201d<\/a><\/li>\n
                20. \u201cHow deep and how many?\u201d<\/a><\/li>\n
                21. The \u201cdue to\u201d clause<\/a><\/li>\n
                22. Three reasons why a performance standard may not be achieved<\/a><\/li>\n
                23. Human Error<\/a><\/li>\n
                24. James Reason \u2013 Psychological Human Error<\/a><\/li>\n
                25. RCM includes Human error<\/a><\/li>\n
                26. Operating context<\/a><\/li>\n
                27. Failure Mode Exercise<\/a><\/li>\n<\/ol>\n

                  Failure Effects<\/h3>\n
                    \n
                  1. Knowledge versus skill<\/a><\/li>\n
                  2. RCM Question 4 \u201cFailure Effects<\/a><\/li>\n
                  3. What is the difference between a Failure Effect and a Failure Consequence?<\/a><\/li>\n
                  4. Repair action \u2013 part of the Effects description<\/a><\/li>\n
                  5. Zero based analysis \u2013 Assumptions when describing the Effects<\/a><\/li>\n
                  6. What should be described in the Effects?<\/a><\/li>\n<\/ol>\n

                    10:30 Coffee Break<\/h3>\n

                    Day 2 1:30 – 2:30 \u201cFailure Consequences<\/a>\u201d<\/h2>\n
                      \n
                    1. RCM Question 5 \u2013 Why does it matter?<\/a><\/li>\n
                    2. Four failure consequences.<\/a><\/li>\n
                    3. Every decision point on the RCM decision algorithm, actually has two questions:<\/a><\/li>\n
                    4. The economics of failure and prevention<\/a><\/li>\n
                    5. Hidden Consequences<\/a><\/li>\n
                    6. Hidden failures<\/a><\/li>\n
                    7. What availability to I want from my protective device?<\/a><\/li>\n
                    8. Who decides what is tolerable?<\/a><\/li>\n
                    9. Tolerable risk of fatality<\/a><\/li>\n
                    10. Probability of being killed on the road or at work<\/a><\/li>\n
                    11. Economic risk<\/a><\/li>\n
                    12. Reducing the probability of multiple failure<\/a><\/li>\n
                    13. Typical hidden functions:<\/a><\/li>\n
                    14. Health, Safety, and Environmental (HSE) consequences.<\/a><\/li>\n
                    15. RCM decision: Two or more proactive tasks<\/a><\/li>\n
                    16. Default tasks<\/a><\/li>\n
                    17. What is tolerable?<\/a><\/li>\n<\/ol>\n

                      2:30 Coffee break<\/h3>\n

                      Day 2 2:45 – 4:30 Failure Management Policies<\/a><\/h2>\n
                        \n
                      1. Questions 6 and 7: The \u201cinitial\u201d failure management policy (slides)<\/a><\/li>\n
                      2. RCM \u201cprefers\u201d\u00a0proactive policies<\/a><\/li>\n
                      3. Line of sight<\/a><\/li>\n
                      4. Time based maintenance (TBM)<\/a><\/li>\n
                      5. The \u201cRCM Curves\u201d<\/a><\/li>\n
                      6. Explanation of the paradox<\/a><\/li>\n
                      7. \u00a0What does the astute manager ask?<\/a><\/li>\n
                      8. Failure pattern B<\/a><\/li>\n
                      9. How to draw the curves<\/a><\/li>\n
                      10. Exercise<\/a><\/li>\n
                      11. How to get the useful life<\/a><\/li>\n
                      12. Condition based (predictive) maintenance<\/a><\/li>\n
                      13. When to maintain?<\/a><\/li>\n
                      14. The basic problem<\/a><\/li>\n
                      15. Add a dimension<\/a><\/li>\n
                      16. Formal definition of CBM<\/a><\/li>\n
                      17. The CBM decision depends on probability and severity<\/a><\/li>\n<\/ol>\n

                        \u00a0The policies FF, NSM, and redesign<\/h2>\n
                          \n
                        1. FFI \u2013 Failure finding interval<\/a><\/li>\n
                        2. No scheduled maintenance<\/a><\/li>\n
                        3. Selecting a default option<\/a><\/li>\n
                        4. \u00a0The goals of redesign<\/a><\/li>\n<\/ol>\n

                          3 Day 3 8:30 – 12:30 Living RCM<\/a> – Achieving reliability from data<\/h1>\n
                            \n
                          1. \n

                            The objectives of LRCM<\/a><\/h2>\n
                              \n
                            1. Objective 1: Work order data quality for RA \u2013 the nature of data<\/a><\/li>\n
                            2. Age data<\/a><\/li>\n
                            3. Condition data<\/a><\/li>\n
                            4. Cost data<\/a><\/li>\n
                            5. The key (EAM-RCM) relationship<\/a><\/li>\n
                            6. Data samples for RA<\/a><\/li>\n
                            7. The meaning of \u201coptimal\u201d<\/a><\/li>\n
                            8. Objective 2: Systematic RCM knowledge improvement<\/a><\/li>\n<\/ol>\n<\/li>\n
                            9. \n

                              LRCM procedures and software<\/a><\/h2>\n
                                \n
                              1. Procedures \u2013 Continuous improvement in the maintenance process<\/a><\/li>\n
                              2. Procedures \u2013 LRCM scheduled activities<\/a><\/li>\n
                              3. Software \u2013 MESH LRCM Modules<\/a><\/li>\n<\/ol>\n<\/li>\n
                              4. \n

                                LRCM Workshop<\/a><\/h2>\n
                                  \n
                                1. Work order data quality<\/a><\/li>\n
                                2. RCM Knowledge continuous improvement<\/a><\/li>\n
                                3. Processing knowledge feedback<\/a><\/li>\n<\/ol>\n<\/li>\n
                                4. \n

                                  Empowerment and recognition<\/a><\/h2>\n
                                    \n
                                  1. Initial RCM dashboard<\/a><\/li>\n
                                  2. Living RCM dashboard<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

                                    4 Day 3 1:30- 4:30 Reliability analysis – Decision modeling<\/h1>\n

                                    Micro (day-to-day decision) analysis<\/a><\/h2>\n
                                      \n
                                    1. Reliability Analysis: 2 dimensions (Statistical and probabilistic concepts)<\/a>\n
                                        \n
                                      1. Reliability analysis is counting<\/a><\/li>\n
                                      2. CBM \u201cpredictive\u201d reliability analysis<\/a><\/li>\n
                                      3. The six RCM curves. What do they really mean?<\/a><\/li>\n
                                      4. Conditional probability of failure<\/a><\/li>\n
                                      5. Conditional failure probability and reliability<\/a><\/li>\n
                                      6. What about the failure rate?<\/a><\/li>\n
                                      7. Random failure. Is it really \u201crandom\u201d?<\/a><\/li>\n
                                      8. Conclusion, so what?<\/a><\/li>\n<\/ol>\n<\/li>\n
                                      9. Weibull Exercises<\/a>\n
                                          \n
                                        1. Perkins marine diesel engine<\/a>\n
                                            \n
                                          1. Problem background<\/a><\/li>\n
                                          2. Problem requirements<\/a><\/li>\n
                                          3. General data<\/a><\/li>\n
                                          4. Event data<\/a><\/li>\n
                                          5. Trend analysis<\/a><\/li>\n
                                          6. Weibull analysis<\/a><\/li>\n
                                          7. Plot the age reliability graphs<\/a><\/li>\n<\/ol>\n<\/li>\n
                                          8. Clutch assembly failures<\/a>\n
                                              \n
                                            1. Grouped data<\/a><\/li>\n
                                            2. Clutch general data<\/a><\/li>\n
                                            3. Clutch event data<\/a><\/li>\n
                                            4. Clutch reliability graphs and report<\/a><\/li>\n<\/ol>\n<\/li>\n
                                            5. Starter motor example that includes suspensions<\/a>\n
                                                \n
                                              1. General data<\/a><\/li>\n
                                              2. Weibull analysis results<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<\/li>\n
                                              3. Optimal maintenance strategies<\/a>\n
                                                  \n
                                                1. Age preventive replacement policy<\/a>\n
                                                    \n
                                                  1. Perkins engine \u2013 maintenance and spares optimization requirements<\/a><\/li>\n
                                                  2. Verify and complete the general data<\/a><\/li>\n
                                                  3. Age preventive replacement policy<\/a><\/li>\n
                                                  4. Spares requirement<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                  5. Interval preventive replacement policy<\/a>\n
                                                      \n
                                                    1. Perkins engine with interval rather than age replacement<\/a><\/li>\n
                                                    2. Interval preventive replacement calculation for Perkins engine fleet<\/a><\/li>\n
                                                    3. Perkins interval replacement policy spares calculation<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                    4. Deterministic replacement policy<\/a>\n
                                                        \n
                                                      1. Data input for a deterministic policy<\/a><\/li>\n
                                                      2. Deterministic policy calculation and results<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n<\/li>\n
                                                      3. Reliability analysis in > 2 dimensions EXAKT basic tutorial<\/a>\n
                                                          \n
                                                        1. What will you learn in this tutorial? <\/a><\/li>\n
                                                        2. Launch EXAKT<\/a><\/li>\n
                                                        3. Create a database (document) for the model<\/a><\/li>\n
                                                        4. Connect the model to the age and CBM data<\/a><\/li>\n
                                                        5. Examine the Inspections table<\/a><\/li>\n
                                                        6. Examine the Events table<\/a><\/li>\n
                                                        7. Examine the other tables<\/a><\/li>\n
                                                        8. Models table<\/a><\/li>\n
                                                        9. Enter general project data<\/a><\/li>\n
                                                        10. Combine the Events and Inspections tables into the C_Inspections table<\/a><\/li>\n
                                                        11. Build a trial model with all four CBM variables<\/a><\/li>\n
                                                        12. Examine the parameter estimation report.<\/a><\/li>\n
                                                        13. Build PH model with all significant variables<\/a><\/li>\n
                                                        14. Eliminate a significant variable<\/a><\/li>\n
                                                        15. Compare the two models<\/a><\/li>\n
                                                        16. Reactivate the model to be retained<\/a><\/li>\n
                                                        17. Goodness of fit<\/a><\/li>\n
                                                        18. Transition model<\/a><\/li>\n
                                                        19. Transition probability matrix<\/a><\/li>\n
                                                        20. Optimal decision policy<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

                                                          Macro (long range) “RAM analysis<\/a>“<\/h2>\n
                                                            \n
                                                          1. RAM Purpose<\/a><\/li>\n
                                                          2. Types of RAM performance predictions<\/a><\/li>\n
                                                          3. \u00a0RAM technique \u2013 Monte Carlo Simulation (MCS)<\/a>\n
                                                              \n
                                                            1. \u201cSimulating\u201d a single mission of 10000 hours<\/a><\/li>\n
                                                            2. Averaging the results of many simulation runs<\/a><\/li>\n
                                                            3. Summary of the RAM MCS method<\/a><\/li>\n
                                                            4. A simple first example<\/a><\/li>\n
                                                            5. Another simple example<\/a><\/li>\n
                                                            6. RAM example 3 \u2013 a complex system<\/a><\/li>\n
                                                            7. RAM example 4 \u2013 a second complex system<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

                                                              Supplemental Day 4-5 “RCM Facilitation”<\/a><\/h2>\n
                                                                \n
                                                              1. Primary function of the facilitator<\/a><\/li>\n
                                                              2. Secondary functions<\/a>\n
                                                                  \n
                                                                1. Required skill sets<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                                2. Facilitating the RCM Q&A process<\/a>\n
                                                                    \n
                                                                  1. Q1 The function statement<\/a><\/li>\n
                                                                  2. \u00a0Q2 The failed states address performance requirements<\/a><\/li>\n
                                                                  3. \u00a0Q3 \u2013 The failure mode<\/a><\/li>\n
                                                                  4. Q3 Which failure modes to include<\/a><\/li>\n
                                                                  5. Q3 The failure mode due to clause<\/a><\/li>\n
                                                                  6. Q3 Failure mode depth and quantity<\/a><\/li>\n
                                                                  7. Q4 Failure Effects \u2013 the story<\/a><\/li>\n
                                                                  8. Q4 Failure effects \u2013 the sub questions<\/a><\/li>\n
                                                                  9. Q5 \u2013 Why does it matter \u2013 the consequences of failure<\/a><\/li>\n
                                                                  10. Q6 \u2013 The PM tasks \u2013 what can be done proactively?<\/a><\/li>\n
                                                                  11. Q6 \u2013 The PM task intervals<\/a><\/li>\n
                                                                  12. Q6 \u2013 Correctly describing the PM tasks<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                                  13. Managing the RCM process<\/a>\n
                                                                      \n
                                                                    1. Prepare for the meetings<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                                    2. Levels of analysis and boundaries<\/a>\n
                                                                        \n
                                                                      1. The advantages of starting high<\/a><\/li>\n
                                                                      2. Other disadvantages of starting too low<\/a><\/li>\n
                                                                      3. Start high then move lower if necessary<\/a><\/li>\n
                                                                      4. Complex components<\/a><\/li>\n
                                                                      5. \u201cRotable\u201d components<\/a><\/li>\n
                                                                      6. Which failure modes to exclude<\/a><\/li>\n
                                                                      7. Minimum jargon and simplified structure<\/a><\/li>\n
                                                                      8. Recognize absence of sufficient knowledge<\/a><\/li>\n
                                                                      9. Avoid redesign in the meeting<\/a><\/li>\n
                                                                      10. Complete the RCM knowledge base<\/a><\/li>\n
                                                                      11. Prepare the audit file<\/a><\/li>\n
                                                                      12. Lead the RCM sessions<\/a><\/li>\n
                                                                      13. Adhering to schedule<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                                      14. Administrating the RCM project<\/a>\n
                                                                          \n
                                                                        1. Project parameters<\/a><\/li>\n
                                                                        2. The schedules and plan<\/a><\/li>\n
                                                                        3. Top management presentation<\/a><\/li>\n
                                                                        4. Initiate a living RCM process<\/a><\/li>\n
                                                                        5. Who is going to be the facilitator?<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n

                                                                          Supplemental Day 5 “Implementing the RCM analysis results”<\/a><\/h2>\n
                                                                            \n
                                                                          1. The RCM audit<\/a>\n
                                                                              \n
                                                                            1. Choice of auditor<\/a><\/li>\n
                                                                            2. Timing of the audit<\/a><\/li>\n
                                                                            3. Audit both process and substance<\/a><\/li>\n
                                                                            4. Common issues for auditor to watch for:<\/a><\/li>\n
                                                                            5. Functions<\/a><\/li>\n
                                                                            6. Failed states<\/a><\/li>\n
                                                                            7. Failure mode issues<\/a><\/li>\n
                                                                            8. Failure effects detail<\/a><\/li>\n
                                                                            9. Consequences attention points<\/a><\/li>\n
                                                                            10. Task concerns<\/a><\/li>\n
                                                                            11. One-off changes:<\/a><\/li>\n
                                                                            12. Justification<\/a><\/li>\n
                                                                            13. Design, implementation, and follow-up<\/a><\/li>\n
                                                                            14. Managing the one-off change<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                                            15. Packaging the RCM tasks<\/a>\n
                                                                                \n
                                                                              1. Maintenance schedules<\/a><\/li>\n<\/ol>\n<\/li>\n
                                                                              2. Systems and Living RCM<\/a>\n
                                                                                  \n
                                                                                1. Planning and control<\/a><\/li>\n
                                                                                2. Continuous improvement<\/a><\/li>\n<\/ol>\n<\/li>\n<\/ol>\n\n","protected":false},"excerpt":{"rendered":"

                                                                                  1 Problem statement Day 1 8:30 – 9:30 When to maintain? (Slides) The basic problem Reliability attributes Wide versus narrow distribution Add a dimension Formal definition of CBM 2 Initial RCM Day 1 9:30 – 12:30 \u201cIntroduction\u201d The definition of RCM (slides) The historical need for RCM Expanding expectations of Maintenance New understanding of\u00a0asset failure […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[94],"tags":[],"class_list":["post-2109","post","type-post","status-publish","format-standard","hentry","category-training"],"_links":{"self":[{"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/posts\/2109","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/comments?post=2109"}],"version-history":[{"count":14,"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/posts\/2109\/revisions"}],"predecessor-version":[{"id":6010,"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/posts\/2109\/revisions\/6010"}],"wp:attachment":[{"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/media?parent=2109"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/categories?post=2109"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.livingreliability.com\/en\/wp-json\/wp\/v2\/tags?post=2109"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}