Reliability Centered Maintenance (RCM) June 14 , 20 20 N7 MSC MSC - - PowerPoint PPT Presentation

MILITARY S SEALIFT C COMMAND

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Reliability Centered Maintenance (RCM)

June 14, 2020

• Maintenance Philosophy
• Reliability Centered Maintenance (RCM)
• MER & SAMM Audit

MSC MSC RCM Pr M Process

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Framework ~ MSC Mission

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MSC’s Maintenance Philosophy

• People:
• Maintain trained, motivated and

forward thinking shipboard personnel and shore side management

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• Tools:
• Provide technology and tools to

analyze equipment operating conditions and maintenance history to enhance maintenance planning and execution

MSC’s Maintenance Philosophy

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Shoreside: MSC IS Portal Shipside Remote Tools

MSC Oil Analyst Combustion Analyst Vibration Analyst

PM, Machinery History, Repair, Workbook Fluid Analysis System (FAS) Combustion Analysis Vibration Analysis Log Book Ships Log LO Expert system Vibration Expert system Master Maintenance Library SMART / CQA PM, Machinery History, Repair, Workbook CMS: Lube Oil Sampling, Vibration, Combustion Log Book Ships Log PENG Feedback Tracking system

Data Replication

PENG SMART / CQA

Data Replication Data Replication

SAMM

Shipboard Users Combustion data collector Vibration data collector

Lighterage Maintenance Management (LAMM)

Pocket PC Ship check Deficiency/Findings collection PENG Availability Staff Smart inspection team CMS Oil Analysis lab

7/23/2008

MSC ENGINEERING APPLICATIONS

Corrective Maintenance

SAMM

Maintenance Decision Support Tool CQA Web Tracker Dexter ( a s r e q u i r e d )

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• Ma

Main intena nanc nce Ma e Mana nagem emen ent A Appr pproach:

• Comply

ly wi with c h commer ercia ial r l regula gulatory a and nd int nter erna natio iona nal r requ quiremen ents

• Ma

Main intain F in Flexibil ibilit ity i in addr dres essing ing m main inten enance e need eds t thr hrough gh a a mix of continu inuous ship’ ip’s f force e main intena enanc nce, t techn hnical r repr presen entativ ive s e servic ice, e, and i nd indus dustria ial a assis istance

MSC’s Maintenance Philosophy

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• Fiscal r

l responsib ibilit ility a and a authority:

• Align l

n life e cycle m le mana nagem emen ent r respo ponsibil ibilit ities ies wi with f h fiscal o

• ver

ersigh ight a and o nd opt ptimiz ize e ship p availa labilit lity f for c customer er requir quirem emen ents u using ng bes est-value p lue prin incipl iples es.

MSC’s Maintenance Philosophy

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• Optim

imiz izatio ion:

• Continu

inue t e to i impr prove l e life c cycle m le mana nagem emen ent and e nd engineer gineering ing p proces esses es

• Evalua

luate a e apply plying ing n new t ew techn hnolo logies ies to impr prove e life c cycle m le mana nagem ement ef effec ectiv ivene ness

MSC’s Maintenance Philosophy

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• Mo

More s simply ly put, th the e 5-Rs Rs:

• Th

The Right ht Maintenance

• on

n the he Right ht Equi quipment,

• at th

t the e Right ht Time e

• with

th th the e Right ht people le

• in

n the he Right ht way ay

• Empl

ploy a an n efficient a and nd cost-effec ective mainten enance a e approac ach t that s strives es t to ensure s e saf afety, m meets regulatory y requirem emen ents a and s supports r reliab ability i y in support of MS MSC m missio ions.

Maintenance Strategy

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Reliability Centered Maintenance

• What is RCM?
• Reliability Centered Maintenance is a

method for determining Applicable & Effective preventive maintenance requirements based on the analysis

• f Machinery History and the

Experience of our Ships’ Personnel

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Commercial & Government Agencies Embrace RCM

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Why I y Implement RCM?

• Common approach to justify Maintenance changes
• Results based on machinery history data
• The justification for the task is recorded
• SAMM Feedback will be adjudicated more quickly
• Eliminate unnecessary non-value added PM
• Accurate and value-added maintenance
• Best practices (detailed narratives)
• Identify Maintenance gaps (3 types)

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What Is “Maintenance”?

Maintenance consists of actions taken to ensure that components, equipment, and systems provide their intended functions when required.

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Understanding Function

• Basic requirement of maintenance is to

preserve function

• Not necessarily design / appearance
• Defining “intended function” properly is

essential

• Procurement specifications set acceptance

criteria

• In-service requirements may be less rigorous

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We do maintenance because:

• We believe hardware reliability

degrades with age

• There is something we can do to

restore or maintain the original reliability

• It pays for itself

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7 RCM Questions

• Function: What function does the hardware

perform?

• Functional Failure: What failure will interrupt the

function?

• Failure Mode: What causes the functional failure?
• Failure Effect: What happens when the failure
• ccurs?
• Failure Consequence: What is the impact of the

failure?

• Task Identification: What action should be taken to

predict or prevent each failure?

• Redesign or No Task Required: What action should

be taken if a proactive task is not identified?

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Amplification

• Functional Failure
• The term that describes the loss of function
• If the function is to provide water at 60 PSI,

100-120 degrees F

• The Functional Failure is - it doesn’t provide

water at 60 PSI, 100-120 degrees F

• Failure Mode
• Material condition of the item after failure (i.e.

seized bearing)

• Reliability
• The ability to provide its intended function

when called upon

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Design/ Build Storage Maintain Operate Install/ Startup

Root Cause Analysis

Loss of Ship Availability and Equipment Downtime Unnecessary Maintenance and Repairs

Defects Defects Defects Defects Defects

Source: Making Common Sense Common Practice 3rd Edition By Ron Moore

Reliability Centered Maintenance

Goal being Reliability

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Three types of maintenance

Type of Maintenance Corrective Preventive Shipalts Characteristic Action Scheduling

Planned / Unplanned Planned (Recurring Action) Planned (One-Time Action)

Sample Tasks

• Technical

representative visits

• Voyage repairs
• Casualty

correction efforts

• Rebuild/restore
• Oil or grease
• Evaluate conditions:
• Vibration analysis
• Infrared imaging
• Performance test
• Discard & replace
• Top off fluids
• ND test
• Oil analysis
• Visual inspections
• Redesign component(s)
• Redesign equipment
• Redesign system(s)

Correct unsatisfactory conditions

Replace Components Other Adjust or Align Components

Minimize unsatisfactory conditions

Diagnose Condition Other Preempt Wearout Test Inspect Restore Replace Check Hidden Function Service

Eliminate unsatisfactory conditions

Modify to Meet Current Requirements (Evolution) Upgrade to Meet New Specifications (Revolution)

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All tasks are Scheduled on a time or situational basis

Maintenance Task Types Condition- Directed Time- Directed Failure Finding Servicing & Lubrication Actions Taken within Procedure “Health Monitoring” Characteristic of a Failure Mode that can be Measured Accurately & Consistently “Life Renewal” (restore or replace regardless of condition) “Hidden Failure” Determine whether a functional failure has already

• ccurred

Service, Refurbish, or Renew Oil, grease or

• therwise

lubricate Circumstance Sufficient Time between Detecting a Problem and Actual Failure Probability of Failure Increases with Time (Wear out) No Measurable Characteristic Failure of off-line or “hidden” function (e.g. Safety/protective devices) Periodic OEM Action Required Maintain Lubrication

Recurring PM Task Types in SAMM

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RCM For CBM

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ABS CM/PM program relies

• n CBM

compliance

Simple W Wearout

Age

Pf

Probability

• f Failure

Wearout Zone

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Comp mplex S Systems ms - Rando ndom F Failur ure Characteris ristic ics

Pf Probability

• f Failure

Complex Systems Age

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Age-Reliability Studies

UAL 1968 Broberg 1973 MSDP Studies 1983 SSMD 1993 SUBMEPP 2001 A. 4% 3% 3% 6% 2% B. 2% 1% 17% 0% 10% C. 5% 4% 3% 0% 17%

Evidence of Wearout

11% 8% 23% 6% 29% D. 7% 11% 6% 0% 9% E. 14% 15% 42% 60% 56% F. 68% 66% 29% 33% 6%

No Evidence of Wearout

89% 92% 77% 93% 71%

Age-Related Random

Age Pf

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Differ eren ent Ages a s at Fai ailure

Source: Reliability-Centered Maintenance, Nowlan and Heap

RfB RfA

Resistance to Failure ( Rf )

Age (operating time, cycles, calendar time)

Stress (σ)

σΒ σΑ

Functional Failure

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Inspection Interval = ½ (F- P) F P F P

Risk Probability x Severity

Sf (Consequence) Pf (Likelihood)

(Fix when failed to condition directed) (Time directed maintenance)

7,500 mi 10,000 mi

• il filter replacement

light bulb

(Fix when failed)

transformer critical regulator 3,000 mi redundant regulators

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Backfit RCM TriFold

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RCM Principle Application: 1st Filter

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Each PM Task is designed to prevent or mitigate a failure mode that will result in a functional failure of the equipment or system

1st

st Filt

ilter: A Age D Degradation

• If
• Delete Task

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• If “yes”, Determine/Classify Task Type…
• CD: Condition Directed
• TD: Time Directed
• FF: Failure Finding
• S: Servicing
• L: Lubrication

…and go to next filter: Applicability

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1st

st Filt

ilter: A Age D Degradation

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1st

st Filt

ilter: A Age D Degradation

…and go to next filter: Applicability

2nd Filter: Applicability

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To answer this question, only apply the Rules for Applicability associated with the Task Type identified in Step 3

2nd Filter: Applicability

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The task only has to satisfy the questions associated with its corresponding task type.

• Does the Task Restore or Maintain Inherent

Reliability?

• If “No”, then Review Improvement Options:
• Can the task be modified to form an Applicable

Task?

• If “Yes”, either
• Change Task Type
• Change scope/requirements
• Change periodicity
• If “No”, Delete the task

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2nd Filter: Applicability

• Does the Task Restore or Maintain Inherent

Reliability?

• If “Yes”, then:

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2nd Filter: Applicability

Identify one or more functional failure consequences the task intended to prevent or mitigate

3rd Filter: Effectiveness

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• In other words: Is the Task Worth Doing?
• Safety and/or Regulatory
• Does the Task Reduce the Probability of failure to an

acceptable level (The probability of failure is never zero.)

• Operational performance (Mission)
• Does this task reduce the risk (Probability X

Consequences) of impacting the mission to an acceptable level

• All other failures
• Is the Cost of PM Less than the Cost of Repair Plus the

Cost of Lost Capability

<

PM

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3rd Filter: Effectiveness

3rd Filter: Effectiveness

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• If the task DOES NOT satisfy its associated area,

then Review Improvement Options

• Can the task be improved to form an Effective

Task? If not, delete the task.

• If the task DOES satisfy its associated area, then

consider whether it can be improved, document any changes, and schedule the Task

• Whether or not a Task satisfies the Rules for

Effectiveness, the Task should be reviewed as to how it could be improved to form an Effective Task, or a More Effective Task by:

• Extending its Periodicity
• Changing the Scope or Requirements
• Combining with related tasks

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3rd Filter: Effectiveness

Backfi fit RCM E M Example

Example No.1

• Maintenance Task – Inspect &

Check Injection Pumps

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Backfi fit RCM E M Example

• Task: M-Code 0498, Inspect & Check Injector

Pumps 12000 hrs

• Functional Failure: Injector Pump Delivery Erratic
• Failure Mode: Loose Pump Bolts
• Does Failure mode Occur in Service?: No, Failure

is highly unlikely to occur in service life.

• Action: Task Deleted

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1st

st Filt

ilter: A Age D Degradation

Example No.2

• Maintenance Task – Inspect Cylinder Heads

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Backfit it R RCM E M Example

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1st

st Filt

ilter: A Age D Degradation

• Task: M-Code 0536, Inspect Cylinder Heads 6000 hrs
• Functional Failure: Inadequate cylinder
• compression. Rough running
• Failure Mode: Cylinder Head Cracks/Valve Assembly

Wear

• Does Failure mode Occur in Service?: Yes
• Action: Identify Task Type and Determine if the Task

is Applicable

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1st

st Filt

ilter: A Age D Degradation

2nd Filter: Applicability

฀ Task: M-Code 0536, Inspect Cylinder Heads

6000 hrs

฀ Task Type – Condition Directed Task ฀ Does the Task Satisfy Applicability Rules?: No,

scale deposit is not quantified or associated with cracked heads or worn valve assemblies

฀ Action: Change to TD Task - Add detailed

procedure to recondition cylinder heads at 12000 hrs, then Identify Functional Failure Consequences and determine if the Task is Effective

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Redesigned Task

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3rd Filter: Effectiveness

• Safety and/or Regulatory - No
• Operational Performance (Mission) –

Yes, loss an engine due to a cracked head would affect mission readiness

• All other failures -
• Cost of PM versus the cost of repair and lost

capability…refurbishing a head is cheaper than a day off-hire

• Action – None; further improvements

unknown

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Example No.3

• Maintenance Task – Check Rocker Arm

Independent Lube Circuit

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Backfit it R RCM E M Example

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Backfit it R RCM E M Example

1st

st Filt

ilter: A Age D Degradation

• Task: M-Code 0508, Inspect & Check Rocker Arm LO

Circuit At 1500 hours

• Functional Failure: Lube oil pump not providing

adequate pressure.

• Failure Mode: Worn pump internals, from debris in

LO.

• Does Failure mode Occur in Service?: Yes
• Action: Identify task type and continue to the

Applicability Filter.

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2nd Filter: Applicability

• Task: M-Code 0508, Inspect & Check Rocker Arm

LO Circuit At 1500 hours

• Task Type – Condition/Time Directed Task
• Does the Task Satisfy Applicability Rules?: No:

Wear is caused by debris in the Lube Oil, so checking Lube Oil pressure only identifies a failure rather than prevent or mitigate it

• Action: Change to a CD task – Lube Oil Sampling,

identify functional failure consequences, and continue to the Effectiveness Filter.

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3rd

rd Filter

er: E Effec ectiven eness s

• Safety and/or Regulatory - No
• Operational Performance (Mission) -

No

• All other failures - Yes
• Cost of PM determined to be less than

the cost of repair and lost capability.

• Action – None

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Reliability Centered Maintenance

Applicability A task or group of tasks is Applicable if it really does prevent, discover or reduce the impact of the failure mode in question. Effectiveness An Effective task that “pays for itself” by mitigating the Risk (safety, regulatory, mission) or Cost of an unplanned loss of equipment function Age Degradation Evidence that the Failure Mode Occurs or is Likely to Occur

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We do maintenance because:

• We believe hardware reliability degrades with

age Does the failure mode occur?

• There is something we can do to restore or

maintain the original reliability Does the Task restore/maintain the Inherent Reliability?

• It pays for itself Is the Task Worth Doing

(Risk/Reward)?

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Document Failures in SAMM

• Define the problem
• What indicated the need for repair?
• What were the operating conditions at the time?
• Did the failure have an immediate impact on the function of the

system?

• Define the Repair
• What was replaced?
• Are there visual indicator of what may have caused them to fail?
• Take and upload pictures in SAMM
• What is the suspected cause of failure? What is the supporting

evidence?

• Did the repair eliminate the symptoms?
• What was done to validate the repair?
• Lessons Learned
• Provide any recommendations to avoid future failures

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SAMM AUDIT

• Simplified Maintenance Effectiveness Review
• Data Analysis:
• Repair data applied against equipment over Five

Years

• PM Conformance is compared to Equipment

Repair History (Age Degradation)

• Periodicity Changes
• Requires Chief Engineers concurrence

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SAMM A AUDIT

Typical Data Analysis Results

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SAMM A AUDIT

Example: Recommended Changes

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Paradigm Shift

“Prove to me that failure won’t occur if you change this.” “Prove to me that failure will occur if I change this.”

Limits of Applicable and Effective Maintenance

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