RCM--Gateway to World Class Maintenance (Reliability-Centered Maintenance)

361 Pages·2003·9.26 MB·English

by  Anthony M. Smith

RCM—GATEWAY TO
WORLD CLASS
MAINTENANCE

RCM—GATEWAY TO
WORLD CLASS
MAINTENANCE
Anthony M. Smith and Glenn R. Hinchcliffe
AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK
OXFORD • PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE
SYDNEY • TOKYO
Elsevier Butterworth–Heinemann
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Library of Congress Cataloging-in-Publication Data
Smith, Anthony (Anthony M.)
RCM : gateway to world class maintenance / Anthony Smith and Glenn R. Hinchcliff.
p. cm.
ISBN 0-7506-7461-X
1. Plant maintenance. 2. Reliability (Engineering) 3. Maintainability (Engineering) I.
Hinchcliff, Glenn R. II. Title.
TS192.S655 2003
658.2—dc22 2003062766
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library.
For information on all Butterworth–Heinemann publications visit our website
at www.bh.com
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Printed in the United States of America
To our wives, Mary Lou and Susan, whose support and belief in our journey made
it all possible.

CONTENTS
Forewordby Jack R. Nicholas, Jr. xiii
Preface xix
Acknowledgements xxi
Chapter 1 World Class Maintenance (WCM)—Opportunity
and Challenge 1
1.1 Some Historical Aspects 1
1.2 Some Common Maintenance Problems 3
1.3 Proliferation of “Solutions” 8
1.3.1 The Acronym Parade 8
1.3.2 Benchmarking and Best Practices—Help or Hindrance? 9
1.4 Maintenance Optimization—An Emerging Vision 11
1.4.1 The Motivating Factor 11
1.4.2 The Traditional Maintenance Mindset 12
1.4.3 Rethinking Maintenance Strategy 13
1.4.4 Focusing Resources—The 80/20 Rule 14
1.5 World Class Maintenance (WCM)—Our Approach 16
Chapter 2 Preventive Maintenance—Definition and Structure 19
2.1 What is Preventive Maintenance? 19
2.2 Why Do Preventive Maintenance? 21
2.3 Preventive Maintenance Task Categories 22
2.3.1 Time-Directed (TD) 23
2.3.2 Condition-Directed (CD) 24
vii
viii Contents
2.3.3 Failure-Finding (FF) 25
2.3.4 CD Versus FF—A Distinction 27
2.3.5 Run-To-Failure (RTF) 28
2.4 Preventive Maintenance Program Development 28
2.5 Current PM Development Practices and Myths 30
2.6 PM Program Elements 33
Chapter 3 The “R” in RCM—Pertinent Reliability Theory
and Application 39
3.1 Introduction 39
3.2 Reliability and Probabilistic Concepts 40
3.3 Reliability in Practice 43
3.4 Some Key Elements of Reliability Theory 46
3.5 Failure Mode and Effects Analysis (FMEA) 49
3.6 Availability and Preventive Maintenance 54
Chapter 4 RCM—A Proven Approach 57
4.1 Some Historical Background 57
4.2 The Bathtub Curve Fallacy 58
4.3 The Birth of RCM 61
4.4 What is RCM? 63
4.4.1 Feature 1 64
4.4.2 Feature 2 65
4.4.3 Feature 3 65
4.4.4 Feature 4 66
4.4.5 The Four Features—A Summary 66
4.5 Some Cost–Benefit Considerations 67
Chapter 5 RCM Methodology—The Systems Analysis Process 71
5.1 Some Preliminary Remarks 72
5.2 Step 1—System Selection and Information Collection 74
5.2.1 Level of Assembly 75
5.2.2 System Selection 76
5.2.3 Information Collection 79
5.3 Step 2—System Boundary Definition 82
5.4 Step 3—System Description and Functional Block Diagram 86
5.4.1 Step 3-1—System Description 88
5.4.2 Step 3-2—Functional Block Diagram 90
5.4.3 Step 3-3—IN/OUT Interfaces 90
5.4.4 Step 3-4—System Work Breakdown
Structure (SWBS) 92
5.4.5 Step 3-5—Equipment History 95
5.5 Step 4—System Functions and Functional Failures 96
Contents ix
5.6 Step 5—Failure Mode and Effects Analysis 98
5.6.1 Functional Failure–Equipment Matrix 98
5.6.2 The FMEA 100
5.6.3 Redundancy—General Rule 106
5.6.4 Redundancy—Alarm and Protection Logic 107
5.7 Step 6—Logic (Decision) Tree Analysis (LTA) 107
5.8 Step 7—Task Selection 112
5.8.1 Step 7-1—The Task Selection Process 112
5.8.2 Step 7-2—Sanity Check 117
5.8.3 Step 7-3—Task Comparison 120
5.9 Task Interval and Age Exploration 124
5.10 Items of Interest (IOI) 127
Chapter 6 Illustrating RCM—A Simple Example
(Swimming Pool Maintenance) 133
6.1 Step 1—System Selection and Information Collection 134
6.1.1 System Selection 134
6.1.2 Information Collection 134
6.2 Step 2—System Boundary Definition 135
6.3 Step 3—System Description and Functional Block Diagram 139
6.3.1 Step 3-1—System Description 139
6.3.2 Step 3-2—Functional Block Diagram 142
6.3.3 Step 3-3—IN/OUT Interfaces 142
6.3.4 Step 3-4—System Work Breakdown Structure (SWBS) 145
6.3.5 Step 3-5—Equipment History 146
6.4 Step 4—System Functions and Functional Failures 147
6.5 Step 5—Failure Mode and Effects Analysis 147
6.6 Step 6—Logic (Decision) Tree Analysis 155
6.7 Step 7—Task Selection 155
6.7.1 Step 7-1—Task Selection Process 155
6.7.2 Step 7-2—Sanity Check 155
6.7.3 Step 7-3—Task Comparison 165
Chapter 7 Alternative Analysis Methods 171
7.1 Reducing Analysis Cost 171
7.2 Abbreviated Classical RCMProcess 175
7.2.1 Step 1—System Selection and Information Collection 175
7.2.2 Step 2—System Boundary Definition 175
7.2.3 Step 3—System Description and Functional
Block Diagram 175
7.2.4 Step 4—Functions and Functional Failures 176
7.2.5 Step 5—Failure Mode and Effects Analysis 176
7.2.6 Step 6—Logic (Decision) Tree Analysis (LTA) 177
x Contents
7.2.7 Step 7—Task Selection 177
7.2.8 Items of Interest (IOI) 177
7.3 Experience-Centered Maintenance(ECM) Process 177
7.3.1 Part A 178
7.3.2 Part B 180
7.3.3 Part C 181
Chapter 8 Implementation—Carrying RCM to the Floor 183
8.1 Historical Problems and Hurdles 184
8.1.1 Equipment-To-Function Hurdle 185
8.1.2 Organizational Hurdle 185
8.1.3 Run-To-Failure Hurdle 185
8.1.4 CD and FF Hurdle 186
8.1.5 Sacred Cows Hurdle 186
8.1.6 Labor Reduction Hurdle 187
8.1.7 PM Task Procedures Hurdle 187
8.1.8 Labor and Material Adjustment Hurdle 188
8.2 Gearing for Success 188
8.2.1 Plan 189
8.2.2 Do 192
8.2.3 Check 192
8.2.4 Act 193
8.3 Interfacing with the CMMS 193
8.3.1 Requirements for CMMS Integrated Support of
RCM Activities 194
8.4 Developing Effective and Useful Task Procedures 197
8.4.1 RCM Rollup 197
8.4.2 Procedural Development 198
Chapter 9 RCM Lessons Learned 203
9.1 Organizational Factors 204
9.1.1 The Structure Factor 204
9.1.2 The Decision Factor 205
9.1.3 The Financial Factor 206
9.1.4 The Buy-In Factor 209
9.2 RCM Teams 210
9.2.1 Resource Allocation 210
9.2.2 Team Makeup 211
9.2.3 Personnel Selection 212
9.2.4 Facilitator Role 212
9.3 Scheduling Considerations 213
9.4 Training 214