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RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Module 5Module 5
UNIT IIUNIT II
RCM PROCESSRCM PROCESSRCM PROCESSRCM PROCESS
IntroductioIntroductionn
IntroductioIntroductionn
Module Preview:Module Preview:Module Preview:Module Preview:
IntroductionIntroductionIntroductionIntroduction
RCM Decision LogicRCM Decision LogicRCM Decision LogicRCM Decision Logic
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
Task EvaluationTask EvaluationTask EvaluationTask Evaluation
Task SelectionTask SelectionTask SelectionTask Selection
Review and SummaryReview and SummaryReview and SummaryReview and Summary
Module Objectives:Module Objectives:Module Objectives:Module Objectives: IntroductioIntroductionn
IntroductioIntroductionn
1. Describe the RCM Decision Logic1. Describe the RCM Decision Logic
2.2. Identify the four types of failure Identify the four types of failure consequences that make up the branches consequences that make up the branches of the RCM Decision Logic treeof the RCM Decision Logic tree
3.3. Describe the RCM Task Evaluation ProcessDescribe the RCM Task Evaluation Process
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Module Objectives:Module Objectives:Module Objectives:Module Objectives: IntroductioIntroductionn
IntroductioIntroductionn
4. Identify the following task types:4. Identify the following task types:
ServicingServicing
LubricationLubrication
On ConditionOn Condition
Hard TimeHard Time
Failure FindingFailure Finding
5. Introduce the RCM Task Selection Process5. Introduce the RCM Task Selection Process
end
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
1. Identify Team and responsibilities 4. Identify and document Review Process2. Identify analysis items 5. Orientation/Training3. Prioritize Items 6. Ground Rules and Assumptions
PLANNING AND PREPARATION
ANALYSIS
RCM ProcessRCM ProcessRCM ProcessRCM Process
AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan
AnalysisAnalysisApproacApproach/ RCM h/ RCM PlanPlan
MaintenanceMaintenanceRequirementsRequirements
MaintenanceMaintenanceRequirementsRequirements
Maintenance Maintenance ProgramProgram
Maintenance Maintenance ProgramProgram
DataDataDataData
1. Equipment Kick-off Meeting2. Initial Data Gathering3. Hardware Partition4. Function5. Functional Failure6. Failure Mode7. Failure Effects8. Failure Consequences9. Task Evaluation10. Task Selection
1. Package Maintenance Task2. Implement Other Actions
ResultsResults
IMPLEMENT RESULTS
1. Emergent Issues2. Age Exploration3. Hardware Changes4. Trend/degrader analysis5. Document Reviews
SUSTAIN
RCM Decision LogicRCM Decision LogicRCM Decision LogicRCM Decision Logic
RCM DECISION LOGICRCM DECISION LOGIC
Process used to determine what action should Process used to determine what action should be taken to eliminate or lessen the be taken to eliminate or lessen the consequences that result from the occurrence consequences that result from the occurrence of a failure modeof a failure mode
RCM Decision LogicRCM Decision LogicRCM Decision LogicRCM Decision LogicPurpose:Purpose:Purpose:Purpose:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?
YESEvident
NOHidden
Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety?
Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety?
YES
EvidentSafety/
Environment
YES
HiddenSafety/
Environment
NO
HiddenEconomic/
Operational
Analyze Options:
S, L, OC, HT,Other Action
Analyze Options:
S, L, OC, HT,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,Other Action
NO
EvidentEconomic/
Operational
Select BEST OPTION
Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?
YESYESEvidentEvident
NONOHiddenHidden
Does failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation?
Does hidden failure mode in combination with second failure/event cause function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation?
YESYES
EvidentEvidentSafety/Safety/
EnvironmentEnvironment
YESYES
HiddenHiddenSafety/Safety/
EnvironmentEnvironment
NONO
HiddenHiddenEconomic/Economic/
OperationalOperational
Analyze Options:
S, L, OC, HT,Other Action
Analyze Options:
S, L, OC, HT,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,Other Action
NONO
EvidentEvidentEconomic/Economic/
OperationalOperational
Select BEST OPTION
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Consequences of FailureConsequences of Failure
FailureFailure ConsequencesConsequencesFailureFailure ConsequencesConsequencesUse of :Use of :Use of :Use of :
Failure consequences:Failure consequences: the impact that the impact that the effects of a failure have on safety, the effects of a failure have on safety, operations, and the environment … and operations, and the environment … and whether the failure is evident to the whether the failure is evident to the operatoroperator
When the failure consequences warrant When the failure consequences warrant attention, the goal of RCM is to control the attention, the goal of RCM is to control the consequences by:consequences by:
•avoiding them (reducing their frequency) avoiding them (reducing their frequency) •reducing their severityreducing their severity
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
• Failure consequences are categorized Failure consequences are categorized in two steps:in two steps:
• Hidden or EvidentHidden or Evident• Safety/Environment or Safety/Environment or
Operational/EconomicOperational/Economic
Identifying:Identifying:Identifying:Identifying:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Identifying:Identifying:Identifying:Identifying: Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
Failure Consequences Step 1:Failure Consequences Step 1:
• Evident FailureEvident Failure: : A failure that, by itself, A failure that, by itself, is is apparent apparent to the operator under normal to the operator under normal circumstancescircumstances
• Hidden FailureHidden Failure: : A failure that isA failure that is not not apparentapparent to the operator under normal to the operator under normal circumstancescircumstances
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Question 1:Question 1:Question 1:Question 1:
Is the functional failure or effect of the Is the functional failure or effect of the failure mode, on its own, EVIDENT to the failure mode, on its own, EVIDENT to the OPERATOR while performing NORMAL OPERATOR while performing NORMAL DUTIES?DUTIES?
EvidentEvident HiddenHidden
Does the failure mode cause a Does the failure mode cause a function loss or secondary damage function loss or secondary damage that could have an adverse effect that could have an adverse effect on operating safety or the on operating safety or the environment?environment?
YESYES NONO
EvidentEvidentSafety/Safety/EnvironmentEnvironment
HiddenHiddenSafety/Safety/EnvironmentEnvironment
EvidentEvidentEconomic/Economic/OperationalOperational
HiddenHiddenEconomic/Economic/OperationalOperational
YESYES NONO NONO YESYES
Does the occurrence of the hidden failure Does the occurrence of the hidden failure mode in combination with a second mode in combination with a second failurefailure /event cause a function loss or /event cause a function loss or secondary secondary damage that could have an adverse damage that could have an adverse effect on operating safety or the effect on operating safety or the environment?environment?
Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
EVIDENT - EVIDENT - Apparent to Apparent to operator without special operator without special monitoring.monitoring.
OPERATOR – OPERATOR – Crew/Equipment OperatorCrew/Equipment Operator
#2
#1
Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
The evident and hidden The evident and hidden groups are further divided groups are further divided based on failure effects:based on failure effects:
• Safety Safety • EnvironmentEnvironment• Operations Operations • EconomicsEconomics
2 Fly-ins2 Fly-ins
Failure Consequences Step 2:Failure Consequences Step 2:
Identifying:Identifying:Identifying:Identifying:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Is the functional failure or effect of the Is the functional failure or effect of the failure mode, on its own, evident to the failure mode, on its own, evident to the operator while performing normal duties?operator while performing normal duties?
EvidentEvident HiddenHidden
Does the failure mode cause a Does the failure mode cause a function loss or secondary damage function loss or secondary damage that could have an adverse effect that could have an adverse effect on operating safety or the on operating safety or the environment?environment?
YESYES NONO
EvidentEvidentSafety/Safety/EnvironmentEnvironment
HiddenHiddenSafety/Safety/EnvironmentEnvironment
EvidentEvidentEconomic/Economic/OperationalOperational
HiddenHiddenEconomic/Economic/OperationalOperational
YESYES NONO NONO YESYES
Does the occurrence of the hidden Does the occurrence of the hidden failure mode/event cause a failure mode/event cause a function loss or secondary damage function loss or secondary damage that could have an adverse effect that could have an adverse effect on operating safety or the on operating safety or the environment?environment?
Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences Question 2:Question 2:Question 2:Question 2:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Is the functional failure or effect of the Is the functional failure or effect of the failure mode, on its own, evident to the failure mode, on its own, evident to the operator while performing normal duties?operator while performing normal duties?
EvidentEvident HiddenHidden
Does the failure mode cause a Does the failure mode cause a function loss or secondary damage function loss or secondary damage that could have an adverse effect that could have an adverse effect on operating safety or the on operating safety or the environment?environment?
YESYES NONO
EvidentEvidentSafety/Safety/EnvironmentEnvironment
HiddenHiddenSafety/Safety/EnvironmentEnvironment
EvidentEvidentEconomic/Economic/OperationalOperational
HiddenHiddenEconomic/Economic/OperationalOperational
YESYES NONO NONO YESYES
Does the occurrence of the hidden failure Does the occurrence of the hidden failure mode in combination with a second mode in combination with a second failure/event cause a function loss or failure/event cause a function loss or secondary damage that could have an secondary damage that could have an adverse effect on operating safety or the adverse effect on operating safety or the environment?environment?
Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences Question 3:Question 3:Question 3:Question 3:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
In summary, failures are In summary, failures are categorized by consequences.categorized by consequences.
RCM uses four categories:RCM uses four categories:• Evident Safety/Environmental Evident Safety/Environmental
• Hidden Safety/EnvironmentalHidden Safety/Environmental
• Evident Economical/OperationalEvident Economical/Operational
• Hidden Economical/OperationalHidden Economical/Operational
Categories:Categories:Categories:Categories:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
Evident failure:Evident failure:• Eliminate/reduce the consequence of Eliminate/reduce the consequence of
single failuresingle failure
Hidden failure:Hidden failure:• Eliminate/reduce consequences of Eliminate/reduce consequences of
multiple failuremultiple failure• Eliminate/reduce economic consequence Eliminate/reduce economic consequence
of single failureof single failure
A A Multiple FailureMultiple Failure is a c is a combination of a ombination of a hidden failure plus a second failure or other hidden failure plus a second failure or other event that makes the hidden failure evidentevent that makes the hidden failure evident
Managing:Managing:Managing:Managing:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Failure ConsequencesFailure ConsequencesFailure ConsequencesFailure Consequences
Safety/Environmental failure:Safety/Environmental failure:• Must prevent the consequences of Must prevent the consequences of
failurefailure
Economic/Operational failure:Economic/Operational failure:• Prevent or allow failurePrevent or allow failure
Summary: RCM decision logic process Summary: RCM decision logic process provides the appropriate management provides the appropriate management strategies for each consequence categorystrategies for each consequence category
Managing:Managing:Managing:Managing:
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
EVIDENTEVIDENT HIDDENHIDDEN
Safety/Safety/EnvironmentEnvironment
Economic/Economic/OperationalOperational
Economic/Economic/OperationalOperational
Safety/Safety/EnvironmentEnvironment
Consequences Consequences Branches:Branches:
Consequences Consequences Branches:Branches:
Analyze Analyze Options:Options:
S, L, OC, HT,S, L, OC, HT,Other ActionOther Action
Analyze Analyze Options:Options:
S, L, OC, HT,S, L, OC, HT,No PM,No PM,
Other ActionOther Action
Analyze Options:Analyze Options:
S, L, OC, HT, FF,S, L, OC, HT, FF,No PM,No PM,
Other ActionOther Action
Analyze Analyze Options:Options:
S, L, OC, HT, FF,S, L, OC, HT, FF,Other ActionOther Action
Select BEST OPTIONSelect BEST OPTION
Failure ConsequencesFailure Consequences Failure ConsequencesFailure Consequences
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Task EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Purpose:Purpose:Purpose:Purpose:
To determine what actions can be taken to To determine what actions can be taken to prevent a failure mode from occurring; or, if not prevent a failure mode from occurring; or, if not prevented, to lessen its effects to an acceptable prevented, to lessen its effects to an acceptable level.level.
Task Task EvaluationEvaluation
Task Task EvaluationEvaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
EVIDENT HIDDEN
Safety/Environment
Economic/Operational
Economic/Operational
Safety/Environment
Analyze Options:
S, L, OC, HT,Other Action
Analyze Options:
S, L, OC, HT,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,Other Action
Select BEST OPTION
Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks: Task EvaluationTask EvaluationTask EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Servicing:Servicing:Servicing:Servicing:
The replenishment of consumable materialsthat are depleted during normal operations.
The replenishment of consumable materialsthat are depleted during normal operations.
Task EvaluationTask EvaluationTask EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Lubrication:Lubrication:Lubrication:Lubrication:
The scheduled lubrication of a component The scheduled lubrication of a component (usually based on the manufacture’s (usually based on the manufacture’s recommendations) where the item’s design recommendations) where the item’s design requires a non-permanentrequires a non-permanent lubricant for proper lubricant for proper operationoperation
Task EvaluationTask EvaluationTask EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
On-ConditionOn-Condition Task EvaluationTask EvaluationTask EvaluationTask Evaluation
Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure.
Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure.
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Hard Time Task:Hard Time Task:Hard Time Task:Hard Time Task:
Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure.
Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure.
Task EvaluationTask EvaluationTask EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Failure Finding:Failure Finding:Failure Finding:Failure Finding:
A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.
A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.
Task EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
5 Fly-ins
Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks:Preventive Maintenance Tasks: Task Task EvaluationEvaluation
Task Task EvaluationEvaluation• S (Servicing Task)S (Servicing Task) - Replenishment of consumable - Replenishment of consumable
materials depleted during normal operationsmaterials depleted during normal operations• L (Lubrication Task)L (Lubrication Task) - Replacement of a lubricant - Replacement of a lubricant
based on manufacturer’s predicted or measured life based on manufacturer’s predicted or measured life of the lubricantof the lubricant
• OC (On Condition Task)OC (On Condition Task) - Periodic or continuous - Periodic or continuous inspection designed to detect a potential failure inspection designed to detect a potential failure condition prior to functional failurecondition prior to functional failure
• HT (Hard Time Task)HT (Hard Time Task) - Scheduled removal of an item - Scheduled removal of an item or a restorative action at some specified age limit or a restorative action at some specified age limit to prevent its functional failureto prevent its functional failure
• FF (Failure Finding Task)FF (Failure Finding Task) - - A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Other Action Warranted:Other Action Warranted:Other Action Warranted:Other Action Warranted:
Other Action: Usually a one time action, other Other Action: Usually a one time action, other than PM, that will effectively reduce the than PM, that will effectively reduce the consequences of failure to an acceptable levelconsequences of failure to an acceptable level
• Item redesignItem redesign
• Change in an operational or maintenance Change in an operational or maintenance procedureprocedure
• Operating restrictionsOperating restrictions
• Etc.Etc.
Task EvaluationTask EvaluationTask EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Other Action Warranted:Other Action Warranted:Other Action Warranted:Other Action Warranted:
Consider when Consider when
• No acceptable PM task can be found for No acceptable PM task can be found for safety/environmental consequence failures safety/environmental consequence failures
• Other Action is preferable to PM and run to Other Action is preferable to PM and run to failurefailure
• Other action, in combination with PM, will Other action, in combination with PM, will beneficially reduce consequences or beneficially reduce consequences or frequency of failurefrequency of failure
Task EvaluationTask EvaluationTask EvaluationTask Evaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
RCM Decision Logic RCM Decision Logic Results:Results:
RCM Decision Logic RCM Decision Logic Results:Results:
Once a failure mode is subjected to the RCM Once a failure mode is subjected to the RCM Decision Logic, at least one of the following Decision Logic, at least one of the following outcomes will result:outcomes will result:
• PM RequiredPM Required
• No PM RequiredNo PM Required
• Other Action WarrantedOther Action Warranted
Task Task EvaluationEvaluation
Task Task EvaluationEvaluation
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Task SelectionTask Selection
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?
YESEvident
NOHidden
Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety?
Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety?
YES
EvidentSafety/
Environment
YES
HiddenSafety/
Environment
NO
HiddenEconomic/
Operational
Analyze Options:
S, L, OC, HT,Other Action
Analyze Options:
S, L, OC, HT,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,Other Action
NO
EvidentEconomic/
Operational
Select BEST OPTION
Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?
YESEvident
NOHidden
Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment?
Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment?
YES
EvidentSafety/
Environment
YES
HiddenSafety/
Environment
NO
HiddenEconomic/
Operational
Analyze Options:
S, L, OC, HT,Other Action
Analyze Options:
S, L, OC, HT,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,No PM,
Other Action
Analyze Options:
S, L, OC, HT, FF,Other Action
NO
EvidentEconomic/
Operational
Select BEST OPTION
Selection Selection Process:Process:
Selection Selection Process:Process:
One or more PM tasks may prevent or reduce One or more PM tasks may prevent or reduce the probability of failure to an acceptable level. the probability of failure to an acceptable level. These tasks along with... These tasks along with...
• a decision to allow the failure mode to a decision to allow the failure mode to occur (no PM)occur (no PM)
• some “other action”... some “other action”...
… … form a pool of options from which solutions form a pool of options from which solutions can be generated.can be generated.
Task SelectionTask SelectionTask SelectionTask Selection
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
Review and Review and SummarySummary
Review and Review and SummarySummary
• IntroductionIntroduction• IntroductionIntroduction
• Learning ObjectivesLearning Objectives• RCM Decision LogicRCM Decision Logic• RCM Decision LogicRCM Decision Logic
• Task EvaluationTask Evaluation• Task EvaluationTask Evaluation
• Task SelectionTask Selection• Task SelectionTask Selection
7 Fly-ins
RCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGICRCM DECISION LOGIC
• Module ObjectiveModule Objective• Module ObjectiveModule Objective
End of Module up next……..
UNIT IIIRCM Software Review
End of Module up next……..
UNIT IIIRCM Software Review