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Reliability Centered Maintenance (RCM) Analysis

Systems Engineering Program. Department of Engineering Management, Information and Systems. EMIS 7305/5305 Systems Reliability, Supportability and Availability Analysis. Reliability Centered Maintenance (RCM) Analysis. Dr. Jerrell T. Stracener, SAE Fellow. Leadership in Engineering.

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Reliability Centered Maintenance (RCM) Analysis

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  1. Systems Engineering Program Department of Engineering Management, Information and Systems EMIS 7305/5305 Systems Reliability, Supportability and Availability Analysis • Reliability Centered Maintenance (RCM) Analysis Dr. Jerrell T. Stracener, SAE Fellow Leadership in Engineering

  2. Introduction • RCMA is a disciplined approach to determine systems Preventive Maintenance (PM) programs. • Candidate items are selected for analysis as early as possible, and re-applied when needed. • For each item, an attempt is made to identify potential failures that are correlated with usage or time passage. • PM tasks may result, depending on criticality and feasibility. • Calculated intervals for identified PM tasks are determined using the best-known life characteristics. • Results are documented.

  3. Introduction • Approach • History of requirements documents • Key Tenets • Conclusions • Sources of information • WWW • Military standards/handbooks • Journal articles • Experience

  4. Commercial Documentation History • MSC-1 (1968, by Boeing Maintenance Steering Group, to support 747 scheduled maintenance program) • MSC-2 (1970, by (ATA) Air Transport Association (ATA) of America and task force of appropriate stakeholders, to support other A/C) • Reliability-Centered Maintenance, Stan Nowlan and Howard Heap, 1978 • MSG-3 (published by the ATA in 1980 to support more-complex A/C, like the 757/767, and address more-stringent FAA regulations and economic issues) Latest revision 2001. • SAE JA1011 (1999) and JA1012 (2002) are “sister” specs

  5. Military Documentation History • Early efforts used commercial docs/reqts • DA PAM 750-40 (USA 1980) • MIK-HDBK-266 (DOD 1981) • MIL-STD-1843 (USAF 1985 (cancelled 1995, no superseding doc.)) • MIL-STD-2173 (USN 1986 (cancelled 1999)) • MIL-STD-2173(AS) (USN 1998 (cancelled 1999)) • NAVAIR-00-25-403 • Late efforts tend to use commercial docs/reqts

  6. Key Tenets • “This process can only address maintenance preventable failures, i.e. it cannot defend against unlikely events, non-predictable acts of nature, etc. ” Wikipedia • Candidates are identified early in a development using Failure Modes and Effects Analysis (FMEA). • Each FMEA candidate is subjected to RCMA. An example of early Army RCM logic tree attached at end of this package. • RCMA can be used with Failure Modes, Effects, and Criticality Analysis (FMECA) per MIL-STD-1629 to identify and assign criticality to potential failures.

  7. Key Tenets (cont) • Results are documented in some fashion. • Existing tool • In-house tool • Logistics Support Analysis Record (LSAR) is a formal data documentation process that can be used to collect results of RCM logic application. • See cancelled MIL-STD-1388-2B • Tools developed per US MIL-STD-1388-2B or MoD 00-60 can be used rather than developing an in-house tool.

  8. Key Tenets (cont) • Application of RCMA may result in: • Servicing Task • Lubrication Task • On-Condition (scheduled inspection) Task • Hard-Time (scheduled removal) Task • Failure-Finding (scheduled inspection of hidden function) Task • No PM Task (if “No PM Task” is unacceptable, then redesign, operational restrictions, change in maint procedures, etc., may be necessary). • Age Exploration • In short, RCMA results in a PM task of some type, system redesign, or an item is allowed to fail.

  9. Conclusions • Generally applied to aircraft and power plant acquisitions. • Generally not applied to US acquisitions that are not new significant systems. • Applied more heavily to smaller acquisitions by UK, Australia, New Zealand, Korea, ROC • RCMA is generally not applicable to electronic items. It applies to items that have increasing failure rate over time, or have inherent wear-out characteristics. • In personal experience, it has not been rigorously applied to any small US system since approximately 1994.

  10. References • Websites • http://assist.daps.dla.mil/quicksearch • http://logistics.navair.navy.mil/rcm/library • http://www.mtain.com/logistics • http://logistics.navair.navy.mil/rcm • Wikipedia • Documents • MIL-STD-2173, MIL-STD-2173(AS) RCM (cancelled) • NAVAIR-00-25-403 RCM • MIL-STD-1388-2B LSAR • MIL-STD-1629 FMECA • Logistics Spectrum, Apr-Jun 2002, Richard W. Anderson

  11. RCM Process Diagram Reference: NAV-00-25-403 (Navy)

  12. RCM Logic Diagram Reference: DA PAM 750-40 (Army). Detailed use instructions are provided (1982).

  13. Full RCM Program Task Sequence Flowchart

  14. Full RCM Program Task Sequence Flowchart (cont)

  15. Full RCM Program Task Sequence Flowchart (cont)

  16. F Collect test and in-service data STEP 28 Does new data support current FMECA and RCM entries? STEP 29 YES NO NO Go to STEP 6 Go to STEP 28 Implement PM tasks STEP 27 Full RCM Program Task Sequence Flowchart (cont) NAVAIR RCM website: http://logistics.navair.navy.mil/rcm/guidance.cfm.

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