MILITARY S SEALIFT C COMMAND Reliability Centered Maintenance (RCM) June 14 , 20 20 N7
MSC MSC RCM Pr M Process • Maintenance Philosophy • Reliability Centered Maintenance (RCM) • MER & SAMM Audit N7
Framework ~ MSC Mission N7
MSC’s Maintenance Philosophy • People: • Maintain trained, motivated and forward thinking shipboard personnel and shore side management N7
MSC’s Maintenance Philosophy • Tools: • Provide technology and tools to analyze equipment operating conditions and maintenance history to enhance maintenance planning and execution N7
MSC ENGINEERING APPLICATIONS Shipside Remote Tools Shoreside: MSC IS Portal SAMM SAMM Oil Analysis CMS Log Book PM, Machinery lab LO Expert PM, Machinery History, Repair, Shipboard Users Dexter system History, Repair, Workbook Workbook Fluid Analysis System (FAS) Data CMS: Lube Oil Ships Log Sampling, Replication Vibration, Combustion Log Book Combustion MSC Oil Analyst Combustion data collector Analysis ) d e r i u q e Vibration Expert r s a ( system Vibration Ships Log Vibration Analysis data collector Combustion Analyst SMART / CQA Master Feedback Maintenance Smart inspection Tracking system Library team Vibration Analyst Data Lighterage Maintenance Replication Management SMART / CQA (LAMM) Deficiency/Findings Pocket PC CQA Web Tracker collection PENG Ship check Data PENG Replication Maintenance Corrective Decision Support Maintenance Tool PENG Availability Staff 7/23/2008 N7
MSC’s Maintenance Philosophy • 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 N7
MSC’s Maintenance Philosophy • 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 over 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. N7
MSC’s Maintenance Philosophy • 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 N7
Maintenance Strategy • 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. N7
Reliability Centered Maintenance • What is RCM? • Reliability Centered Maintenance is a method for determining Applicable & Effective preventive maintenance requirements based on the analysis of Machinery History and the Experience of our Ships’ Personnel N7
Commercial & Government Agencies Embrace RCM N7
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) N7
What Is “Maintenance ”? Maintenance consists of actions taken to ensure that components, equipment, and systems provide their intended functions when required. N7
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 N7
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 N7
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 occurs? • 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? N7
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 N7
Goal being Reliability Design/ Storage Install/ Operate Maintain Build Startup Defects Defects Defects Defects Defects Loss of Ship Availability and Root Cause Analysis Equipment Downtime Reliability Unnecessary Maintenance and Repairs Centered Maintenance Source: Making Common Sense Common Practice 3 rd Edition By Ron Moore N7
Three types of maintenance Type of Corrective Preventive Shipalts Maintenance Correct unsatisfactory Minimize unsatisfactory Eliminate unsatisfactory conditions conditions conditions Characteristic Diagnose Condition Preempt Wearout Adjust or Replace Modify to Meet Upgrade to Meet Action Align Components Current New Components Specifications Test Inspect Restore Requirements Replace (Evolution) (Revolution) Other Check Hidden Other Service Function Planned / Scheduling Planned (Recurring Action) Planned (One-Time Action) Unplanned • Technical • Rebuild/restore • Discard & replace • Redesign component(s) representative • Oil or grease • Top off fluids • Redesign equipment visits • Evaluate conditions: • Redesign system(s) • Voyage repairs Sample Tasks - Vibration analysis - ND test • Casualty - Infrared imaging - Oil analysis correction - Performance test - Visual inspections efforts N7
Recurring PM Task Types in SAMM Maintenance Time- Condition- Servicing & Task Failure Finding Directed Lubrication Directed Types “Health Service, Monitoring” Refurbish, or “Hidden Failure” “Life Renewal” Characteristic of Actions Renew (restore or Determine whether a Failure Mode Taken within replace a functional failure that can be regardless of has already Procedure Oil, grease or Measured condition) occurred otherwise Accurately & lubricate Consistently Probability of Failure Periodic OEM Sufficient Time Failure of off-line or Increases with Action Required between “hidden” function Time Circumstance Detecting a (e.g. (Wear out) Problem and Safety/protective Maintain Actual Failure devices) No Measurable Lubrication Characteristic All tasks are Scheduled on a time or situational basis N7
RCM For CBM ABS CM/PM program relies on CBM compliance N7
Simple W Wearout Probability Wearout of Failure Zone P f Age N7
Comp mplex S Systems ms - Rando ndom F Failur ure Characteris ristic ics Complex Systems Probability of Failure P f Age N7
Age-Reliability Studies UAL Broberg MSDP Studies SSMD SUBMEPP 1968 1973 1983 1993 2001 P f A. 4% 3% 3% 6% 2% Age - Related Age B. 2% 1% 17% 0% 10% C. 5% 4% 3% 0% 17% 11% 8% 23% 6% 29% Evidence of Wearout D. 7% 11% 6% 0% 9% E. 14% 15% 42% 60% 56% Random F. 68% 66% 29% 33% 6% 89% 92% 77% 93% 71% No Evidence of Wearout N7
Differ eren ent Ages a s at Fai ailure Inspection Interval = ½ (F- P) Functional R fA Failure R fB Resistance Stress (σ) to Failure P P ( R f ) σ Β σ Α F F Age (operating time, cycles, calendar time) Source: Reliability-Centered Maintenance , Nowlan and Heap N7
Risk Probability x Severity critical regulator light bulb (Fix when failed) P f (Likelihood) oil filter replacement transformer 10,000 mi (Time directed redundant maintenance) regulators (Fix when failed 7,500 mi to condition directed) 3,000 mi S f (Consequence) N7
Backfit RCM TriFold N7
RCM Principle Application: 1 st Filter Each PM Task is designed to prevent or mitigate a failure mode that will result in a functional failure of the equipment or system N7
st Filt 1 st ilter: A Age D Degradation • If • Delete Task N7
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