Course Overview

Contrary to common believes that equipment failures are inevitable, many organizations in the aerospace industries have shown that with proper IDENTIFICATION, ANALYSIS, STRATEGY, zero failures are possible and can be achieved.

What we lack now is proper methodologies for achieving it.

Finding the root cause of a failure is important but what is more and very important is proactively eliminating the potentials of failures.   

We must transform our reactive maintenance culture to that of proactive culture. We must Prevent failures before it strikes.

RCM with it’s concept of FMECA and failure consequences, identifies all potential failure modes whether it is visible or hidden. and proactively eliminates them before it occurs.

Methodology

Since the subject requires real hands on practise, only some simple examples will be used to narrate the understanding and the phase progression. For a very effective understanding a in-house program is more appropriate.

However, participants are encouraged bring sample failure incidences for discussion.   

Trainer will provide the formats for phase 1 – 4.

Learning Outcomes

Participants will understand Reliability Centered Maintenance (RCM) how to :

• – Establish asset functions
• – Establish asset failures and failure modes.
• – Conduct an equipment FMECA (S,O,D)
• – Establish failure consequences.
• – Establish RPN rating and ranking.
• – Using the decision diagram for corrective action
• – Reassessing the potential RPN (PRPN)
• – Final resulting RPN (RRPN)

Who Should Attend

• Maintenance managers
• Maintenance engineers
• Maintenance supervisors.
• Senior maintenance technicians.

Course Content

Module 1: Introduction to RCM.

• What is RCM.
• The core of RCM
• Brief history of RCM
• 7 basic foundation questions of RCM
• RCM is a five step process.
• 4 phase of RCM implementation.
• How to measure equipment reliability.

Module 2 : Develop equipment block diagram.

• List all main modules
• List all sub-modules.
• Identify all failure potential components in every module.

Module 3 : Develop phase – 1 functions and failure modes

• Determine function of components
• Establish the performance standard for every component
• Potential functional failures
• Failure modes causing the failures
• List all failure effects.

Module 4 : Develop phase 2 – conduct FMECA  and consequences

• Understand severity, occurrence and detection.
• Rating methodologies for S, O, D.
• Establishing the RPN.
• Failure consequences
• Safety consequences.
• Environment consequences.
• Operation consequences.
• Non-operation consequences.
• All hidden failure consequences.

Module  5 : Develop phase 3 – determine proactive actions

• Establish the failure mode ranking
• Perform why? Why?  For every failure mode
• How to use the RCM decision diagram
• Brainstorm for permanent proactive actions.
• Test the solutions for effectiveness.

Module 6 : Develop phase 4  – assessing  PRPN   &  RRPN

• Establish new potential S, O, D.
• Determine what to do, when to do.
• Clearly assign responsibility.
• Perform proactive task.
• Determine actual resulting RRPN.