RCM - Maintenance Philosophy of the Future?

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RCM - Maintenance Philosophy of the Future?

• by Peter Ormond, Strategic Corp., Australia

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Reliability Centred Maintenance

• Original paper by Nowlan and Heap, 1978
• Major re-work in RCM II by John Moubray
• SAE Standard JA1011 in 1999

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Maintenance Philosophies
Predictive or Condition Based Maintenance
Preventive or Change-out Maintenance
Reliability Centred Maintenance
Breakdown Maintenance
Mid 60s
Mid 80s
Industrial Revolution
Second World War
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BHPs Experience

• Steel Industry World Wide Review
• Man-hours per Liquid Tonne of Steel
• Four Best Practice Organisations
• Biggest difference Maintenance treated as a
  PROFIT CENTRE
• BHP was managing Maintenance as COST CENTRE

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BHP Action Plan

• Understand Problem
• Set Overall Target
• Target 40 Reduce in Maint. Cost Per Tonne in 5
  years
• Develop Approach for Solution
• 7 Step Plan

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Education

• Develop a new technique for applying training -
  SBL
• Develop a high level training package
• Introduction to Maintenance and its Management
• Apply training package to ALL employees

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Roles Responsibilities

• New understandings required new definitions
• Some changes to organisational structure
• Once-off exercise

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Measurements

• The only way to make permanent change is to
  change the way things are measured
• Split measurements between KPIs and the PIs
  that feed them
• KPIs are ALL Historical, Summary and
  UNCONTROLLABLE
• Measuring is not enough, interpreting the
  measures is the important step

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Processes and Systems

• Follow-on from all the previous steps
• Includes fully developed processes, procedures,
  documentation, etc.
• Also includes adequate computer systems, both
  hard and software, as well as appropriate training

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Strategy Based Maintenance

• Understand Profit Centre Maintenance
• Travel World looking for solutions
• RCM recognised as fitting exactly with required
  philosophy
• Love results Hate effort required
• Develop Methodology to enhance RCM (RCM Turbo)

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Continuous Maintenance Improvement

• Appoint responsibility
• Formalise process
• Recognise shortcomings of P-D-C-A
• Change Act to AUTHORISE

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BHPs 7 Step Plan

1. Re-Education
2. Re-Define Roles Responsibilities
3. Re-Develop Measurements
4. Provide Processes and Systems
5. Apply Strategy Based Maintenance
6. Formalise Continuous Improvement
7. Focus on Waste Reduction

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Waste Reduction

• Very similar to Continuous Maintenance
  Improvement
• Look outside normal Maintenance sphere
• Same structure but less frequent

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BHP Steels Results

• Achieved 50 reduction in 6 years
• Pointed to two factors having greater impact than
  anticipated
• Re-Education of all employees into common
  understanding of Maintenance
• Implementation of RCM (RCM Turbo)

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World Wide View

• Late 80s
• Paper based analyses
• Several successful exercises
• No PC Tools
• Almost no-one had heard of RCM

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World Wide View

• Mid90s
• Many heard of RCM but few knowledgeable
• Several Tools
• Other systems claiming to be RCM
• SAE Standard JA1011

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World Wide View

• Current 2000
• Few organisation not heard of RCM
• Most organisations have some-one with detailed
  knowledge
• Many organisations have Reliability Group
• Many others trying to start projects
• RCM Incorporated into University Courses

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How does it all fit together?

• Business Plan

• Plant Strategy

• Operating requirements
• Inventory plant items
• Life Plans for critical plant items
• (RCM analysis)

Document Retrieval System Work instructions
CMMS Task lists Maintenance plans Work orders

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RCM-Turbo The Versatile Tool
Review
KPI
Scheduling
Improvement Steps
Resource Bal
Grp Tasks
Opt Freq
Task Analysis
Fail Analysis
Equip Codes
Reactive Maintenance Systems Maturity Proactive
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RCM-Turbo The Versatile Tool
Review
KPI
Scheduling
Improvement Steps
Resource Bal
Grp Tasks
Opt Freq
CMMS
Task Analysis
Fail Analysis
Equip Codes
Reactive Maintenance Systems Maturity Proactive
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RCM-Turbo The Versatile Tool
Review
KPI
RCM
Scheduling
Improvement Steps
Resource Bal
Grp Tasks
Opt Freq
CMMS
Task Analysis
Fail Analysis
Equip Codes
Reactive Maintenance Systems Maturity Proactive
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RCM-Turbo The Versatile Tool
RCM-Turbo
RCM-Turbo
Review
KPI
RCM
Scheduling
Improvement Steps
Resource Bal
Grp Tasks
Opt Freq
CMMS
Task Analysis
Fail Analysis
Equip Codes
Reactive Maintenance Systems Maturity Proactive
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Frequency Optimisation
MTBF
Total Annual Business Cost of Maint.
Cost of Failure
Cost of Inspection
Time
Optimum Frequency
FTM - Optimum Frequency based on Probability of
Failure in MTBF
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Warning Time
P
F1
F
70 Confidence non-failure
92 Confidence non-failure
Warning Time
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Frequency Optimisation
MTBF
Total Annual Business Cost of Maint.
Cost of Failure
Cost of Planned Repair
Cost of Inspection
Time
Optimum Frequency
Warning Time
CBM - Optimum Frequency based on Confidence of
non Failure in Warning Time
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Frequency Optimisation Graph
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Benefits Obtained from Frequency Optimisation

• Many Tasks Increase in Frequency Increasing
  Reliability
• Many Tasks Reduce in Frequency Reduced Costs
  without Compromising Reliability
• Average Cost Reduction 10 15
• Assists What If..? Scenario Testing
• Justification of Maintenance Decisions

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Benefits of RCM

• Changing Organisations to Profit Centre rather
  than Cost Centre Maintenance
• A Methodology to apply Business Decision to
  Maintenance Planning
• Supports all Current Maintenance Techniques
• Consistent with and sub-part of TPM

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Title Question

• RCM Maintenance Philosophy of the Future?

YES !