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DOFR Redesign the shaft with One time cost. Life enhanced to 10 years. No
shoulders < 5% change Cost equal to loss of productivity due to
in diameter & change original shaft shaft breakage. No recurring
material cost. Life cycle costs much
lower, low inventory.
Maintenance free
Problem: A grease lubricated bearing of a high speed
fan seizes frequently. Life approximately one year
Method Actions Cost Effects
Traditional Replace bearing as High Loss of productivity.
and when it breaks Recurring cost
RCM Monitor bearing life Cost lower than If opportunities are not
with vibration Traditional method available then there is a
monitoring and (since opportunity loss of productivity
replace during utilized) but not otherwise only a cost of
opportunity eliminated. Recurring replacement is incurred.
cost remains Recurring Cost.
DOFR Redesign with oil One time cost Life enhanced to three
lubricating system years. No loss of
since D x N > 3500 productivity No
recurring cost. Life cycle
cost much lower; low
inventory. Maintenance
free
Problem: In a steel mill, journal bearings seized rather
randomly. There were 28 reported cases in a period of one
year
Method Actions Cost Effects
Traditional Pay attention to lubrication. Pay High Loss of productivity.
attention to fitting and tolerances. Recurring cost, High
Replace when damaged inventory. High maintenance
efforts.
Before After