reliability centered design

Abstract: One of the more common tools utilized as part of a Condition-Based Maintenance (CBM) program is Reliability-Centered Maintenance (RCM). The RCM process is a front-end program designed to develop a maintenance program to provide the right maintenance, on the right equipment, at the right time and for the right reasons. Unfortunately, most RCM programs do not contain a continuous improvement aspect as many assume that the rigorous process will provide accurate and sustainable results. However, with this process, errors do occur and changes to technology, or the identification of improved tests and inspections not identified during the process, may change the best practice maintenance identified through the process. With the implementation of a program developed within the military, the Maintenance Effectiveness Review, a continuous improvement process can be implemented.

The authors, having been involved with RCM from its first introduction to the U.S. commercial and industrial world in the early 1980s, have experienced virtually every characteristic that contributes to successful and likewise not-so-successful RCM programs. In this chapter, we will attempt to give you the benefits of our 35-plus combined years of RCM experience and the lessons we and others have had to learn along the way. It is our hope that, by knowing where the more significant potholes lurk, you may avoid them. Our discussion here will focus on four of the key Lessons Learned, but we encourage you to see our entire discourse on this subject in Reference 1, pages 203-221.

The role of RCM in the facilities (non - production) environment as expected varies dramatically with the age and type of facility being operated and maintained thus, the type of RCM to be applied must be carefully decided to ensure both tangible and intangible benefits will be realized within the budgetary constraints of the organization. In addition, the dynamics of the organization where RCM is being considered must be considered before selecting the optimum approach. For example, an organization involved in large scale construction and/or renovation will have substantially different requirements and resultant business case than one focused on sustaining the status quo via a maintenance and minor repair approach.

Tragedy at Sea

On January 8, 2005 the USS San Francisco was transiting the open waters of the Pacific when she experienced arguably the heaviest blow to befall a US Navy submarine in decades. Unbeknownst to the ship's crew an undersea mountain lay directly in her path. Suddenly the ship slammed bow first into the obstruction at 30 or more knots - severely damaging the vessel and injuring most all aboard.