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A logical discipline for developing a scheduled-maintenance program that will realize the inherent reliability levels of complex equipment at minimum cost. RCM provides a framework to organize maintenance activities within an organization.
Chris and Fred discuss how to analyze reliability data for repairable spares—and why the “as good as new” assumption can be dangerously misleading. They explore how maintenance itself can introduce new failures and distort your analysis.
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The management of spare parts and inventories is all about balance between the cost of stocking the parts and the costs and risks of not having them when they are required.
As a consultancy owner, one of the most overlooked issues I see in Industrial operations is the management of spare parts. I don’t have enough fingers, toes and limbs to count how many times I’ve heard the phrase ” The machine is down because we’re waiting on spare parts”.
I see this phrase normalised so often that people don’t bat an eye and have accepted it as the norm- a lot of maintenance professionals don’t focus on the effective management of this area . I think this is overlooked because it requires MATH to calculate- and just like poetry, most people hate math. [Read more…]
In this video we touch on all 7 steps of the RCM process as we introduce one of the most important aspects of the application of RCM…asking the people who really know!
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Have you ever tried to implement any asset improvement activity but it didn’t go so well? Couldn’t rally the troops? Couldn’t get the kind of management buy-in that you really needed to get things off the ground? If so, you’re not alone.
I’ve read too many articles describing that up to 70% of asset improvement initiatives fail. And I think it’s because a lot of people don’t have a basic understanding of maintenance and reliability principles. So they don’t understand why “change” needs to take place.
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Air, sea, space, land, or underground? Commercial, government, or military? Reliability Centered Maintenance has something for everyone!
Absolutely. In fact, in Stanley Nowlan and Howard Heap’s book on RCM, they state:
The content of scheduled-maintenance programs developed by experienced practitioners of MSG-2 techniques may be quite similar to the programs resulting from RCM analysis, but the RCM approach is more rigorous, and there should be much more confidence in its outcome. The RCM technique can also be learned more quickly and is more readily applicable to complex equipment other than transport aircraft.
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Absolutely not. This is one of the biggest misconceptions of the RCM process. Discover why it is often wrongly believed that RCM is too difficult to implement.
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RCM is one of the most powerful maintenance and reliability improvement processes out there. The name Reliability Centered Maintenance lends itself to a process that’s used to develop proactive maintenance for an asset – and it is. But RCM can be used to formulate scores of solutions that reach far beyond maintenance.
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There is a big difference between Preventive Maintenance Optimization (PMO) and Reliability Centered Maintenance (RCM). Daffodils are a perfect way to explain the difference.
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Despite their shared emphasis on maintenance, Total Productive Maintenance (TPM) and Reliability Centered Maintenance (RCM) are not competing strategies.
Manufacturers can create a powerful synergy to leverage the strengths of each if they understand their respective strengths. Such a combination leads to exceptional reliability, cost-effective maintenance, and improved corporate culture – if implemented successfully. [Read more…]
Instead of allocating time and resources trying to force the same maintenance method on every asset in your facility, reliability centered maintenance (RCM) offers you a more structured and proven approach where each piece of equipment is allocated a befitting maintenance strategy based on the results of a well-executed RCM analysis.
I had a conference call this morning with some potential clients in regard to rolling out a RCM Blitz™ effort. The sad thing about Reliability Centered Maintenance is the reputation the tool has acquired over the last 40 years has one of two faces.
The sad, tragic and more popular face is that if the Resource Consuming Monster. The reputation that RCM is too detailed, that it takes too long, and that by the time you finish your analysis there are no recourses and there is no money left for implementation. According to a survey conducted on ReliabilityWeb.com nearly 70% of all RCM implementations fail, with statistics like this, it is a wonder the tool still exists. [Read more…]
Like it or not we live in a society where we like to keep score. The score provides feedback; it gives those who are not involved information on the progress or success of those who are involved. The score can be delivered in an endless number of formats, the price of your company stock, net profits, unit cost of product, overall equipment effectiveness, or percent emergency/demand maintenance. In the world of Reliability Centered Maintenance RCM Guru Jack Nicholas gathered a team of experts several years ago to develop the RCM Scorecard. The result of this effort was a comprehensive tool that evaluated Key Performance Indicators at various periods before and during an RCM Project. [Read more…]
RCM Implementations don’t fail, believe me if you understand what your getting into upfront, use a proven process to select your asset for analysis AND you commit the resources, your implementation will be a huge success.
Looking back 20 years I can clearly remember performing my first RCM analysis and the ordeal that followed as we struggled to:
a) See the value in the analysis we had just completed (Someone told us that RCM should be performed on every piece of equipment at our plant so we selected one of our most common assets.
b) Free up the resources necessary to implement the tasks that came out of the analysis. [Read more…]
Reliability Centered Maintenance is a powerful tool that when applied and implemented correctly can provide numerous benefits including improved equipment reliability, a reduction in unplanned downtime and lower unit cost of product. One of the most impressive benefits of performing a RCM Blitz™ analysis is the identification of failure modes that could result in a health, safety and environmental incident or accident. While some would like to believe that in today’s world where most new designs and capital projects are subjected to numerous design reviews that would include process hazard analysis we still uncover a significant number of health, safety and environmental related failure modes in every RCM Blitz™ analysis. [Read more…]
I had a conference call this morning with some potential clients in regard to rolling out a RCM Blitz™ effort. The sad thing about Reliability Centered Maintenance is the reputation the tool has acquired over the last 40 years has one of two faces.
The sad, tragic and more popular face is that if the Resource Consuming Monster. The reputation that RCM is too detailed, that it takes too long, and that by the time you finish your analysis there are no recourses and there is no money left for implementation. According to a survey conducted on ReliabilityWeb.com nearly 70% of all RCM implementations fail, with statistics like this, it is a wonder the tool still exists. [Read more…]
