Reliability Centered Maintenance (RCM) Analysis Last revised 01/14/2011
Introduction The Reliability Centered Maintenance analysis is integrated into the FMECA toolkit, which allows you to leverage the relational nature of the FMECA to provide you with identified end effects and conditional probabilities for each failure mode in the system. In addition ASENT’s FMECA Manager will allow you to quickly update your analysis assuring that your results are current any time failure rates are updated or item descriptive data (name, part number, description, etc) is changed. The relationship between failure modes and effects and the tree structure are automatically tracked by the toolkit so that updates can easily be made at any time.
Selecting the RCM Analysis Method The first step is to select the RCM analysis method. This is done in the Session Manager, which is the first ASENT tool that is invoked. Select the project you will work on, then select the RCM method from the ‘RCM Type’ drop down box. Click on the Save button. Now right click on the project and Select ‘FMECA Manager’ to enter the FMECA.
Recommended Methodology 1) Run the ‘Check FMECA’ utility and resolve any outstanding problems. 2) From the FMECA Library Editor, enter any predefined Preventive Maintenance Tasks into the RCM Task Library. All that is needed is the task name. 3) Start at the Assemblies at the bottom of the tree and work toward the top of the tree. The intermediate assemblies will have many of the same results and tasks as the lower level assemblies. 4) Analyze one failure mode using the questionnaire, based on the results, add PM tasks as appropriate, and order the tasks as they should be performed, entering the interval for the tasks. 5) Copy the RCM results to any other failure mode where the same results and tasks apply. 6) Add any notes unique to any use of a PM task application on a given failure mode. 7) Generate the RCM reports and review for content and completeness. Depending on your situation, there might not be a need to generate all 7 reports. Generate the reports on one assembly and refine it to your satisfaction, then proceed to the next assembly.
Extensive use of libraries reduces data entry and errors Data entry and errors are significantly reduced by the extensive use of libraries in the tool. The Notes/Status field allows you to enter data, comments or notes that will apply to all uses of the task. The navigation buttons and their meanings are shown below.
Starting the Analysis To begin the analysis, select an assembly and click on the ‘RCM’ Tab. The first failure mode is selected by default, and the RCM results for this failure mode are displayed above the Failure Mode Grid. Press the ‘Analyze’ button to perform the analysis for this failure mode.
Analyzing Failure Modes The RCM Questionnaire displays the System Level effect for the selected failure mode along with the severity of the system level effect. The first set of questions categorizes the significance (structural or functional) the Failure Mode contributes to the Assembly. Click on a check box to answer the question. The next appropriate question will be presented The ‘Abort’ button exits the questionnaire and leaves the results unchanged. A ‘Back’ button is available after the first question to allow you to back up, in case you answered the previous question incorrectly.
Completing the RCM Questionnaire After the questionnaire has determined the significance, the set of questions for that type significance is presented. The questionnaire will exit when the last appropriate question has been answered.
Displaying & Copying Results After the questionnaire is completed, the results are displayed in the Failure Mode grid and summarized in the area above the grid. Click in the RCM Tasks Grid and add Tasks.
Adding PM Tasks The task drop down contains all the tasks entered in the library. Select the task. Enter the interval that the Task should be performed. The Prelim Int is the interval when the system is in use. The Packed Int is when the system is in storage. Enter the Maintenance Level (Where the PM task will be performed). Select the task type from The drop down list.
Finalizing PM Data Once the PM tasks are entered, you can add a description or note that is unique to this use of the PM Task By pressing the ‘Edit Task Notes’ button or ‘Add Task Desc’ button. Pressing either of these buttons opens a panel where you can enter additional data. (Up to 255 characters) The red arrows allow you to set the order of the Tasks as they will appear in the report. Copying the RCM data, including PM tasks, can save you a lot of time and effort where the same result and tasks apply. Press the Copy RCM button to copy the data.
Copying RCM Data To copy RCM data from one failure mode to one or more other failure modes, select a failure mode and then click on the ‘Copy RCM’ button. Next, select the Assembly to receive the data. The tree of the present function/phase is presented. Expand it until the assembly of interest is displayed. After selecting the assembly and pressing the ‘OK’ button, the failure modes for the selected assembly are displayed. This is a multiple select window, with the items in blue being selected. The standard Ctrl+Click and Shift+Click selection methods are available. Press the ’OK’ button when the failure modes you want are all selected. The data, including the PM Tasks are copied to the selected failure modes.
Generating RCM Reports The Assy Type field in ASENT gives you control over which assemblies are included in your RCM report. Assemblies with a blank assembly type are automatically excluded from the report. Selecting RCM Reports from the reports drop down menu of the Assembly menu displays the RCM Reports option panel. Select an Assembly type from the bottom window and check the reports you want. You can run this report for a single assembly or an entire subtree by clicking the ‘Include SubAssemblies’ check box. The Excel workbook, with a page for each selected report, is generated.