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.
[Read more…]Articles tagged Reliability Centered Mainteance (RCM)
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.
Daffodils explain the difference between Preventive Maintenance Optimization (PMO) and RCM…
There is a big difference between Preventive Maintenance Optimization (PMO) and Reliability Centered Maintenance (RCM). Daffodils are a perfect way to explain the difference.
[Read more…]Why Total Productive Maintenance Is The Answer To Reliability-Centered Culture
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…]
5 Tips For Improving RCM With A CMMS
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.
The Two Faces of RCM
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…]
Scoring Your RCM Effort
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…]
The Recipe for RCM Success!
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…]
Reduce Health, Safety & Environmental Incidents & Accidents With Reliability Centered Maintenance
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…]
Why Do You Need Reliability Centered Maintenance?
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…]
The Dangers of RCM Shortcuts!
When people first begin to learn about Reliability Centered Maintenance and methodologies like RCM Blitz, they get excited about the potential results that can come from performing a RCM analysis and implementing the resulting tasks. Shortly after completing their RCM Training some begin to understand that good RCM takes leadership, structure and discipline, others begin to think of ways to shortcut the process. [Read more…]
Fast Track RCM: Improving Plant Performance & Profitability
A Proven Framework to Improve Performance and Build Ownership of the Equipment
Understanding the how equipment failures along with utilizing a proven and effective approach to developing an equipment strategy is a winning combination for manufacturers everywhere. When combing the knowledge and the system, manufacturers can yield significant improvements in their operation, such as a reduction in PM workload of 22% with gain 4% in line efficiencies. Or how about a reduction of 42% of PMs, without a single loss in equipment availability. It is possible and required for manufacturers to become and remain profitable. [Read more…]
Uptime: Managing Failures Before They Occur
Being proactive with your assets is all about managing failures before they occur. You can reduce or eliminate the consequences of failure by forecasting what is likely to happen and deciding in advance about what to do about it. The advantage to doing this is that major business impact due to equipment breakdown can be avoided. High performing companies manage proactively – they foresee and avoid problems. It’s good for business! [Read more…]
Linking RCM Facilitation with Effective Maintenance Program Implementation
Most of us would agree that there is a new global economy being forged right now in the manufacturing sector.
Inevitably, this translates to a renewed focus on transferring more business value to the customer. Central to this will be linking RCM (Reliability Centered Maintenance) facilitation with effective maintenance program implementations.
In short, the difference between what we, as RCM Facilitators, have been doing in the past and what we will be doing from now on is: a strong emphasis on what tactics are required in order to achieve the failure management strategies an RCM Team defines.
That is, we will conduct the decisions phase of the analysis somewhat differently. (i.e. The 3rd pass through when walking-the-dog in an RCM analysis) [Read more…]
Cracks in the Road
“Dave is the guy we call when we need to get the plant up and running again; there really isn’t anything he can’t fix.”
Dave sits back in his chair, he looks down and while he is smiling I can see he is slightly embarrassed by the praise his manager is heaping on him.
It’s clear to me that he is not comfortable sitting in this conference room with a group of people that includes his manager, supervisor, and two engineers who are here to kick off their first RCM analysis. I have just begun asking the group to introduce themselves; Dave followed his manager and the two engineers in the room who each rattled off where they attended college, what their degrees they earned, the areas of the plant they are responsible for, their hobbies outside of work and some banter regarding the upcoming college football season.
Then it was Dave’s turn. [Read more…]
RCM Leaders and Followers
Funny how times change.
When I first began speaking at conferences in 1999 some of the statements I made regarding how to most effectively manage a Reliability Centered Maintenance program were publically criticized by practitioners of other methodologies.
Sixteen years later it seems that those who were at first critical of RCM Blitz® seem to have adopted nearly every change I made to make RCM easier to Manage, Facilitate and provide a return on investment (ROI) for the time it takes to train people, perform the analysis, implement the results, and perform the RCM tasks. [Read more…]