Reliability Centered Maintenance

1. Reliability Centered Maintenance

2. Vibration Analysis Reliability Failure Analysis Oil Analysis Performance Analysis Condition Monitoring

3. Root Cause Failure Analysis • Analysis of Failure • Confirmation of Analysis • Real Reason for failure • Prevention of Failure • Approach to RCFA • Why Why analysis • Ishikawa Diagram

4. RCFA • Why- Why Steps • Bearing Failed • Why? • Spall in Inner Race • Why? • Caused by Over Load • Why? • Belt Load More • Why? • And So on till you cannot further breakdown.

5. RCFA • Ishikawa Diagrams Foreign Matter Lubrication Bearing Failed Skewed Pulley Unbalance Belt Lack of Training Overload Over Tightening

6. Reliability Centered Maint.

7. RCM – 7 Questions • What are the functions and associated performance standards in present operating context? • In what ways does it fail to fulfill its functions? • What causes each functional failure? (Modes) • What happens when each failure occurs? (Effects) • In what way does each failure matter? (Consequences) • What can be done to predict or prevent each failure? • What should be done if a suitable proactive task cannot be found?

8. Step 1 – Define Failure • What are the possible failures • List all failures • Example • Pump Does not give Flow • Pump does not give Pressure • Pump Has High Vibration • Pump Has High Noise

9. Step2 – Identify Modes • Six distinct modes of Failure • Traditional – Increasing probability of failures with age • Modified – Decreasing, Steady and Increasing probability – Bath Tub Curve • Modern – Additional 4 modes

10. Modes of Failure 1 2 % Prob 5 3 6 4 Time

11. 1 2 5 3 6 4 Time Failure Modes

12. Step 3 – Identify Effects • Effects of Each Failure Mode in the Particular Failure Type • Example • High Vibration • Mode  Type 6 • Effect  Unreliable operation • Cracking of supports • Brinneling of bearings etc…

13. Step 4 –Identify Consequences • Identify Consequences for each effect • Example • Support Cracks • Consequences  Leakage & Fire • Environmental Degradation

14. Step 5 – How to Predict / Prevent • Identify Prediction and Prevention for each Failure • Driver is Consequence • More Severe Consequence  Prevention & Prediction • Failure Prevention • Proactive Task • Default Actions

15. Step 6 – Task Application • Proactive Tasks • Restoration Task – PM Concept • On Condition Task – PdM/ CBM Concept • Default Actions • Failure Finding • Redesign • Run-to-failure

16. Step 6 – Task Selection • Cost to Benefit Analysis • Consequence Evaluation • Environment Consequece  Predict & Re-Design • Operation Consequence  Prevent And So on…

17. In Conclusion • RCM • Primarily a Risk recognition & Mitigation technique • Involves detailed documentation • Effective in Combination • With FMEA or RCFA • With TPM & TQM

18. End of Part -5