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WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY 1
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Reliability Centered Maintenance & Maintenance Planning Jordan Holt Director Performance Improvement
Francesco Palmeri | CRE. PMP, PE Director Reliability Centered Maintenance Planning
Washington Metropolitan Area Transit Authority
Key References
a. Nowlan & Heap (Dec 1978), Reliability Centered Maintenance, United Airlines, San Francisco, CA, USA.
b. John Moubray (1990), RCM2, Industrial Press Inc, NY, USA
c. SAE International Standard JA1011 (Aug 2009), Evaluation Criteria for RCM Processes
d. SAE International Recommended Practice JA1012 (Aug 2011), A Guide to the RCM Standard
e. Marius Basson (2018), RCM3, Industrial Press Inc, NY, USA
Another very useful reference
a. Doc Palmer (1999), Maintenance Planning & Scheduling 3rd Edition, McGraw Hill, NY, USA
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•
• •
•
Historical Timeline of the Notable Developments in RCM
MSG in aviation
1960 MSG 1&2 deveby aviation industry
loped 1980 MSG3
1988 MSG3 Rev 1
1993 MSG3 Rev 2 2001 MSG3.2 001
2002 MSG3.2 002
The development of RCM
1978 Nowlan & Heap
1981 RCM appli
1986
report “RCM” pub
ed outside aviation for the first time
MIL STD 2173 Nav
lished
air 404 NES 45
1999 SAE JA1011 & SAE JA1012
Aladon RCM2/3
1990 John Moubray “RCM2”
2004 “RCM3” Risk-based RCM
WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY
1960 1970 1980 1990 2000 2010 2020 WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY 3
Formal Definitions
What is Reliability Centered Maintenance (RCM)? Nowlan & Heap: A logical discipline for the development of scheduled maintenance programs to realize the inherent reliability capabilities of equipment.
RCM2: A process used to determine what must be done to ensure that any physical asset continues to do what its users want it to do in its current operating context.
RCM3: A process used to define the minimum required safe amount of maintenance, engineering and other risk management strategies to ensure a tolerable level of safety and environmental integrity and cost effective operational capability as specified in the organization’s asset management standards.
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-- -- - -
Steps of the RCM3 Process
The eight (8) steps of RCM3: Step 1: What are the operating conditions? (Define the operating context) Step 2: What are the functions & performance stds? (What do users want it to do) Step 3: In what ways can it fail? (Define the failed states) Step 4: What causes it to fail? (Determine failure causes & mechanisms) Step 5: What happens when it fails? (Determine failure effects & consequences) Step 6: What are the risks associated with each failure? (Inherent risks) Step 7: What must be done to reduce intolerable risks to a tolerable level? (Proactive risk management)
Step 8: Can anything be done to reduce tolerable risks in a cost effective way? (Default risk management)
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Proactive Risk Management
Risk = Probability x Consequences
In order to reduce an Intolerable risk to a Tolerable level, we have three (3) choices. We could:
a. Reduce the Probability of occurrence through proactive maintenance,
b. Reduce the Severity of consequences through a one-time change (modification, training, change in process or procedures),
c. If possible; do both (depending on the severity of the consequences).
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-- -- - -
Proactive Task Options
Predictive or condition-based maintenance
Preventive maintenance – scheduled restorations
Preventive maintenance – scheduled discards
Failure finding tasks (only for protective devices)
Functional checks
One-time changes (Modification, Training, Procedures).
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Fundamentals of Maintenance & Reliability
Generation I – Maintenance / Design Philosophy Run everything to failure - repair or replace as required (Run to failure)
Generation II – Maintenance / Design Philosophy Assume all components have a useful life limit. Replace components before they reach that useful life limit (Safe life)
Add redundancy (Fail safe)
WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY 8
Fundamentals of Maintenance & Reliability
Generation III – Maintenance / Design Philosophy Design for Reliability - only do maintenance when required (Damage tolerant) Introduce Condition Monitoring Adopt a Condition Based Maintenance approach
Generation IV – Maintenance / Design Philosophy Industrial Internet (IIoT) Making use of the real time data capture and wireless technology Integration with the Computerized Maintenance Management System
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I I I I I I I I I I I I I I I I
I I I I I I I I I I I
~
Fundamentals of Maintenance & Reliability
Idealized bathtub curve model for the time to failure of a component Hazard Rate
Time
Useful Life Infant Mortality Wear Out
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--------
WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY
Fundamentals of Maintenance & Reliability
Idealized effect of Maintenance on the bathtub curve
Preventative
Haza
rd R
ate
Useful Life Infant
Mortality Wear Out
Maintenance
Extension of Useful Life
Time 11
~~-----------------------------------------
WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY
Fundamentals of Maintenance & Reliability
Realistic effect of Maintenance on the bathtub curve Ha
zard
Rat
e
• Maintenance • Overhauls • Modifications
Reemergence of the Infant Mortality
Region
Time 12
I I I I I I I I I I I I I I I
I I I I I
~ WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY
Fundamentals of Maintenance & Reliability
Idealized view of maintenance optimization Ha
zard
Rat
e
Useful Life Infant
Mortality Wear Out
Best window to perform
maintenance
Time 13
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b
Historical Failure Patterns
Research shows the following six failure patterns across many industries. Originally performed by United Airlines and Boeing as part of the 747 program (MSG 1 & 2)
4%4%4% AAA
2 %2 %2 % BBB
5 %5 %5 % CCC
7 %7 %7 % DDD
E14 %14 %14 % EE
F68 %68 %68 % FF
GGeenenerarallllyy aapppplilieess ttoossimimpplele iitteemmss oorr ccoommpplelexx ititeemmss wwiitthh ddoomminainantnt fafaililureure mmooddeess..
AsAsssoocciaiatteedd wwiitthh ccoommpplleexx eeqquipuipmmeentnt ssuucchh aasseelleeccttroroniniccss,, hhydydraraululicic aanndd ppnneeumumaatticic ssysystteemmss..
11% - Might benefit from
limit on operating age
89% -No benefit
from limit on operating age
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Useful Life
Mean Life
Average Lost Life
Explaining Useful Life
Time
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What does all this mean for WMATA
Historically, WMATA relies on OEM maintenance program for the entire lifecycle of our Assets’
Time Based Maintenance is prevalent
Little to No consideration of Operational Performance and/or Changes to our Operating Context
Little to No consideration of adopting a Condition Based Maintenance approach
PM Compliance is consistently above 90% and yet over 40% of our maintenance is corrective action
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WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY
Benefits of Adopting a Condition Based Maintenance Approach
P- F Interval
Cond
ition
Time
Condition Monitoring allows you to maximize the P-F Interval and move to a Proactive maintenance culture
F Point where
Failure occurs
Point where Failure begins
P
Point where Failure can start to be
Measured
Oil Analysis (Months)
Thermography (Weeks)
Vibration (Weeks - Months)
Acoustics (Weeks)
Smoke (Secs)
Heat (Days)
17
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RCM3 Decision Diagram
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WASHINGTON METROPOLITAN AREA TRANSIT AUTHORITY
-~rov_ed M$lnt .. Poll . . cy_
*
P.lannin.g . & .
~ullrig_
~8 · Worl(
Documeot Work_
RCM & Maintenance Planning
**Analyze performance** of programs in place and loop back if further refinement required
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-- -- - -
RCM & Maintenance Planning
RCM at WMATA Around 100 people trained via six 3-day sessions Six deep dives conducted with 7th planned
• Chosen based on reliability reporting • Switches, track circuits, DC breakers, Track/third rail, Railcar pneumatic system, Railcar doors
• Two weeks (about a week on proces and a second week on the system) • Cross-section of maintenance, operations and engineering staff
Working through implementing deep dive recommendations
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Common Myths about RCM
“It’s too hard…”
“It takes too long…”
“It’s too expensive….”
“That’s just an Aviation thing; it won’t work in our industry….”
“That’s just another name for condition monitoring….”
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Summary
RCM is a process (structured, scientific, repeatable, defendable)
It is not new…….RCM has been around for over 40 years
When applied correctly, RCM will provide the best maintenance program for your Asset given the Operating Context & Risk profile.
Step 7 provides the pathway for addressing Risk proactively
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