RELIABILITY CENTRED MAINTENANCE (RCM)

1. RELIABILITY CENTRED MAINTENANCE (RCM) Application within RCAF and Implementation in OmegaPS Mike Martin

2. BRIEFING OUTLINE • Maintenance Environment within RCAF • RCM Process (MSG-3) • Principles of RCM • Significant Item Selection • Functional FMEA • Level 1 & 2 Decision Logic • Task Assignment and Packaging • Implementation in OmegaPS (FRCM) M. Martin

3. MAINTENANCE ENVIROMENT WITHIN RCAF • Maintenance Program part of Design • Changes tightly regulated • Conduct of Maintenance on aircraft / equipment recorded and controlled • Support to Legacy fleets becoming more challenging M. Martin

4. WHAT IS RCM? • A Definition: • RCM is a structured process to identify the appropriate level of preventive maintenance for an item to: • Retain inherent levels of performance, reliability and safety • Minimize cost of maintenance and failures over the life cycle • Primary Objectives: • Ensure safety through PM actions; when PM cannot effectively ensure safety, redesign is mandatory • When safety is not a concern, preserve functionality in the most economical manner with the least impact on Operations M. Martin

5. WHY DO RCM? • New Programs: • Requirement of design (ICAs) • Identify APPLICABLE and EFFECTIVE scheduled maintenance tasks • Initial programs conservative and generic • Legacy Programs: • Able to modify generic programs to suit environment and fleet performance • Structured, disciplined approach to substantiating proposed Design Changes M. Martin

6. FLAVOURS OF RCM • ATA/MSG-3 (***) • RCM II • NAVAIR 00-25-403 • NAVSEA S9081-AB-GIB-010 • DEF STAN 02-45 • Etc If any question about whether or not a process meets RCM requirements consult: SAE JA1011 – Evaluation Criteria for RCM Processes M. Martin

7. STEPS TO PERFORM RCM • Step 1: Identify MSI • Step 2: Perform Functional FMEA • Step 3: Apply MSG-3 Decision Logic • Level 1 – Failure Effect Code • Level 2 – Task Identification • Step 4: Package Maintenance Tasks M. Martin

8. MAINTENANCE SIGNIFICANT ITEMS(MSIs) • Objective of MSI selection: select appropriate systems / components for analysis • Why be selective? • A/C equipment and systems have many components and parts • Analysis of every component on an aircraft would be unrealistically costly and time consuming • Failure of many items have no immediate impact on the a/c as a whole • RCM derived maintenance program directs tasks where they matter – at Significant Items M. Martin

9. STEP 1 – IDENTIFY MSIs • Partition equipment into major functional areas • Top-down approach; identify items at highest manageable level • Item is MSI if failure could: • adversely effect safety • Have major operational or economic consequences • Be undetectable during normal operations • If in doubt, item should be selected as an MSI M. Martin

10. PARTITION EQUIPMENT M. Martin

11. MSI SELECTION DECISION LOGIC M. Martin

12. STEP 2 - FUNCTIONAL FMEA M. Martin

13. RESULTS OF FMEA • For each MSI: • - List of High Level Functions • For each Function: • - List of Functional Failures • For each Functional Failure: • - List of Failure Effects • For each Failure Effect: • - List of Components which cause this Functional Failure/Failure Effect to Occur M. Martin

14. EXAMPLE OF FMEA EXAMPLE ONLY M. Martin

15. STEP 3 – APPLY MSG-3 DECISION LOGIC • LEVEL 1 – Identification of Functional failure Effect (FEC) • LEVEL 2 – Identification of APPLICABLE and EFFECTIVE Preventive Maintenance Task M. Martin

16. MSG-3 LEVEL 1 & 2 DECISION LOGIC M. Martin

17. LEVEL 1 DECISION LOGIC M. Martin

18. LEVEL 2 DECISION LOGIC M. Martin

19. EXAMPLE OF LEVEL 1 / 2 EXAMPLE ONLY M. Martin

20. STEP 4 – TASK PACKAGING • Select Significant Intervals • Fit Others into this interval or multiples • Group Individual Tasks Together By: • Location • Trade • Complexity • Frequency M. Martin

21. SAMPLE INSPECTION CARD M. Martin

22. TYPICAL INSPECTION Inspection Tasks (4 trades) M. Martin

23. CURRENT TOOLS • AEPM Performa • ADAM data from the field • Extracted into Excel files • Maintenance Analyzer (ATESS) • Access Database • MSI • FMEA • Level 1 / 2 analysis • Audit • MS Excel M. Martin

24. CURRENT TOOLS • Card Deck • Access Database • MS Word Templates • Contactor Database (IETM) • ???? • Scheduling / Planning • MS Project / MS Excel • Paper • ???? M. Martin

25. FUNCTIONAL RCM (FRCM)IN OmegaPS M. Martin

26. FRCM MODULE • Create FUNCTIONAL structure • MANAGE analysis assignments • Perform FMEA • Audit FMEA • Perform Level 1 / Level 2 analysis • Assign Task and Interval • Audit Level 1 / Level 2 and Task analysis M. Martin

27. CREATE FUNCTIONAL STRUCTURE M. Martin

28. SELECT FUNCTIONAL RCM MODULE M. Martin

29. FUNCTIONAL TREE STRUCTURE M. Martin

30. MANAGER M. Martin

31. DEVELOP FMEA M. Martin

32. OmegaPS FMEA Worksheet M. Martin

33. LEVEL 1 ANALYSIS M. Martin

34. LEVEL 2 ANALYSIS M. Martin

35. LEVEL 1 / LEVEL 2 REPORT M. Martin

36. TASK / INTERVAL IDENTIFICATION M. Martin

37. POTENTIAL OmegaPS MODULE INTEGRATION PoM FRCM ANALYZER LORA PUBLISHER M. Martin

38. Questions?