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STEP 1 Develop/update RCM Program Plan

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STEP 1 Develop/update RCM Program Plan - PowerPoint PPT Presentation


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STEP 2 New Equipment Design Recommended. STEP 2B. STEP 3. Complete End Item & Level 1 Breakdown. SSWG. System Safety input to Severity Classification of failure modes. Select Severity Class for the failure mode. STEP 10. STEP 4. Complete Level 2 Breakdown.

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Presentation Transcript
slide1

STEP 2

New

Equipment Design Recommended

STEP 2B

STEP 3

Complete

End Item & Level 1 Breakdown

SSWG

System Safety input to

Severity Classification of failure modes

Select

Severity Class for the failure mode

STEP 10

STEP 4

Complete

Level 2 Breakdown

Calculate or estimate failure distribution curve

STEP 13

STEP 2

Current

Equipment Design

STEP 2A

STEP 11

Complete

FMECA.

Complete

Levels 3 and 4 Breakdowns

STEP 5

Calculate or estimate time to first failure

STEP 14

STEP 8

Identify

all functional failures and Compensating Provisions

STEP 12

Collect failure and

test data

Identify

all functions

STEP 6

STEP 9

Identify

all failure modes and their failure effects (Local, Next Higher & End Effects)

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

STEP 1

Develop/update

RCM Program Plan

STEP 7

Perform

Functional Significance Determination for each function

FUNCTIONAL SIGNIFICANCE DETERMINATION LOGIC

Does the loss of function have an adverse effect on safety or environment?

Yes

No

Does the loss of function have an adverse effect on operations?

Yes

No

Does the loss of function have an adverse effect on economic?

Yes

No

Is this function protected by an existing PM task?

Yes

No

NON-SIGNIFICANT FUNCTION

SIGNIFICANT FUNCTION

Select a failure mode for RCM Analysis and perform

STEPS 11 thru 23

Steps 8 and up steps are not to be performed for this function.

Perform STEP 7 for next function.

RELIABILITY ANALYSIS

RCM ANALYSIS TASKS

REDESIGN / CIP TASKS

IMPLEMENTATION TASKS

A

OTHER EVENTS

OPERATIONS

FEEDBACK TASKS

FMECA TASKS

2 - 7

2 – 8 (Blank)

slide2

STEPS 18

Answer

failure consequences questions.

(MODULE 10)

Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?

Develop

Other Action

STEP 18E

Develop

Other Action

Develop

Failure Finding PM task

STEP 18F

STEP 18E

YES

NO

EVIDENTDoes the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation?

HIDDEN

Does the occurrence of the hidden failure mode in combination with a second failure / event cause a function loss or secondary damage that could have an adverse effect on operating or lead to serious environmental violation safety?

NO

NO

YES

YES

Evident

Safety / Environment

Evident

Economic / Operational

Hidden

Economic / Operational

Hidden

Safety / Environment

STEPS 18A THRU 18F REQUIRED INFORMATION (as applicable, not all data required for all FM’s)

Description for each task

Determine

Number of OC or PHM tasks required during PF interval to meet Pacc

Determine

PM intervals for all tasks

Determine

Single task total man-hours and cost

STEP 18B

Develop

Servicing / Lubrication PM task

STEP 18A

Develop

PHM task

STEP 18A

Develop

Servicing / Lubrication PM task

STEP 18B

Develop

PHM task

Will this failure mode happen within the

service life of the equipment?

STEP 15

Develop

On-Condition PM task

STEP 18C

Develop

On-Condition PM task

STEP 18C

Determine whether failure has PF, wear out, or random type failure characteristics

STEP 16

STEP 17

Determine or estimate PF condition, PF-FF interval or wear out/life limit age

Develop

Hard Time PM task

STEP 18D

Develop

Hard Time PM task

STEP 18D

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

A

NO

YES

Steps 16 and up steps are not to be performed for this failure mode.

GO TO STEP 23

B

C

D

E

2 - 7

2 – 8 (Blank)

slide3

Repeat

STEPS 11 thru 23 until all FM(s) have been analyzed

STEP 23

STEP 19

Determine costs associated with each STEP 18A thru 18F item

+

No action taken costs

Determine costs associated with each STEP 18A thru 18E item

STEP 19

STEP 19

Determine costs associated with each STEP 18A thru 18F item

Determine costs associated with each STEP 18A thru 18E item

+

No action taken costs

STEP 19

Review RCM results with SSWG, FST, maintainers and operators for inputs.

(MODULE 14)

STEP 24

Analysis/ Select

which option or combination of options is best at meeting RCM metrics

STEP 20

STEP 20

Analysis/ Select

which option or combination of options is best at meeting RCM metrics

STEP 20

Analysis / Select

which option or combination of options is best at meeting RCM metrics

STEP 25

Perform

Packaging Process

Review RCM results with designers and potential operators/maintainers for inputs

STEP 24

Perform LORA and update maintenance plan

STEP 26

Provide

usage prediction data (STEP 13) to logistics to ensure adequate replacement parts are available

STEP 21

Go to

STEP 2B

Develop

Age Exploration task

STEP 22

Direct PM task to be implemented regardless of RCM results

PMA / APML

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

B

C

C

D

E

Is hardware in-service or undergoing design testing?

Analysis/ Select

which option or combination of options is best at meeting RCM metrics

STEP 20

Design Testing

In-service

*

*

*

PM Task/s required

Redesigned required

Redesigned required

No action

required

PM Task/s required

PM Task/s required

Redesigned required

Recommended PM acceptable?

YES

NO

NO

GO TO

STEP 2B

GO TO

STEP 2B

No additional analysis is required.

GO TO STEP 23

Was engineering judgment / estimated values used during any part of the RCM analysis?

* -

YES

NO

F

slide4

Collect

test and in-service data

STEP 28

Does new data support current FMECA and RCM entries?

STEP 29

Go to

STEP 6

Go to

STEP 28

Implement

PM tasks

STEP 27

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

F

YES

NO

NO

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