RCM - Maintenance Philosophy of the Future?

by Peter Ormond, Strategic Corp., Australia

Reliability Centred Maintenance

Original paper by Nowlan and Heap, 1978 Major re-work in RCM II by John Moubray SAE Standard JA1011 in 1999

Maintenance Philosophies
Breakdown Maintenance
Preventive or Change-out Maintenance Predictive or Condition Based Maintenance Reliability Centred Maintenance

Industrial Revolution

Second World War

Mid 60s

Mid 80s

BHPs Experience

Steel Industry World Wide Review

Man-hours per Liquid Tonne of Steel Four Best Practice Organisations Biggest difference Maintenance treated as a PROFIT CENTRE

BHP was managing Maintenance as COST CENTRE

BHP Action Plan

Understand Problem Set Overall Target

Target 40% Reduce in Maint. Cost Per Tonne in 5 years 7 Step Plan

Develop Approach for Solution

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Education

Develop a new technique for applying training - SBL Develop a high level training package

Introduction to Maintenance and its Management

Apply training package to ALL employees

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Roles & Responsibilities

New understandings required new definitions Some changes to organisational structure Once-off exercise

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Measurements

The only way to make permanent change is to change the way things are measured Split measurements between KPIs and the PIs that feed them KPIs are ALL Historical, Summary and UNCONTROLLABLE Measuring is not enough, interpreting the measures is the important step

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Processes and Systems

Follow-on from all the previous steps Includes fully developed processes, procedures, documentation, etc. Also includes adequate computer systems, both hard and software, as well as appropriate training

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Strategy Based Maintenance

Understand Profit Centre Maintenance Travel World looking for solutions

RCM recognised as fitting exactly with required philosophy Love results Hate effort required

Develop Methodology to enhance RCM (RCM Turbo)

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Continuous Maintenance Improvement

Appoint responsibility Formalise process Recognise shortcomings of P-D-C-A Change Act to AUTHORISE

BHPs 7 Step Plan

1.
2. 3. 4. 5. 6. 7.

Re-Education Re-Define Roles & Responsibilities Re-Develop Measurements Provide Processes and Systems Apply Strategy Based Maintenance Formalise Continuous Improvement Focus on Waste Reduction

Waste Reduction

Very similar to Continuous Maintenance Improvement Look outside normal Maintenance sphere Same structure but less frequent

BHP Steels Results

Achieved 50% reduction in 6 years Pointed to two factors having greater impact than anticipated:

Re-Education of all employees into common understanding of Maintenance Implementation of RCM (RCM Turbo)

World Wide View

Late 80s

Paper based analyses Several successful exercises No PC Tools Almost no-one had heard of RCM

World Wide View

Mid90s

Many heard of RCM but few knowledgeable Several Tools Other systems claiming to be RCM SAE Standard JA1011

World Wide View

Current 2000+

Few organisation not heard of RCM Most organisations have some-one with detailed knowledge Many organisations have Reliability Group Many others trying to start projects RCM Incorporated into University Courses

Business Plan Plant Strategy

(RCM analysis) CMMS Task lists Maintenance plans Work orders

How does it all fit together?

Operating requirements Inventory plant items Life Plans for critical plant items

Document Retrieval System Work instructions

RCM-Turbo The Versatile Tool

Improvement Steps
Review KPI Scheduling Resource Bal Grp Tasks Opt Freq Task Analysis Fail Analysis Equip Codes

Reactive

Maintenance Systems Maturity

Proactive

RCM-Turbo The Versatile Tool

Improvement Steps
Review KPI Scheduling Resource Bal Grp Tasks Opt Freq Task Analysis Fail Analysis Equip Codes

CMMS

Reactive

Maintenance Systems Maturity

Proactive

RCM-Turbo The Versatile Tool

Improvement Steps
Review KPI Scheduling Resource Bal Grp Tasks Opt Freq Task Analysis Fail Analysis Equip Codes

RCM

CMMS

Reactive

Maintenance Systems Maturity

Proactive

RCM-Turbo The Versatile Tool

RCM-Turbo

Improvement Steps

RCMTurbo
Review KPI Scheduling Resource Bal

RCM

Grp Tasks Opt Freq Task Analysis Fail Analysis Equip Codes

CMMS

Reactive

Maintenance Systems Maturity

Proactive

Frequency Optimisation
MTBF

Total Annual Business Cost of Maint.

Cost of Failure

Cost of Inspection Time

Optimum Frequency
FTM - Optimum Frequency based on Probability of Failure in MTBF

Warning Time
P
F1 F

70% Confidence non-failure 92% Confidence non-failure Warning Time

Frequency Optimisation
MTBF

Total Annual Business Cost of Maint.

Cost of Failure Cost of Planned Repair Cost of Inspection Time

Optimum Frequency

Warning Time

CBM - Optimum Frequency based on Confidence of non Failure in Warning Time

Frequency Optimisation Graph

Benefits Obtained from Frequency Optimisation

Many Tasks Increase in Frequency Increasing Reliability Many Tasks Reduce in Frequency Reduced Costs without Compromising Reliability Average Cost Reduction 10% 15% Assists What If..? Scenario Testing Justification of Maintenance Decisions

Benefits of RCM

Changing Organisations to Profit Centre rather than Cost Centre Maintenance A Methodology to apply Business Decision to Maintenance Planning Supports all Current Maintenance Techniques Consistent with and sub-part of TPM

Title Question

RCM Maintenance Philosophy of the Future?

YES !