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Marc Banghart

Reliability Centered

Maintenance Analysis

Systems Reliability, Supportability and Availability

Analysis

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Marc Banghart

Cost of Maintenance and Repair

Obtained from the RCM Guide, NASA September 2008

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Marc Banghart

What is RCM?

• The purpose of RCM

– Identify policies that preserve the function of anasset in its operating context…

– Preserve the function…not just maintain the

equipment

• RCM ensures that:

– The right maintenance is performed

– At the right time

– By the right people

– In the right way

– With the right training and tools

•

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What is RCM? (continued)

RCM considers:

– Scheduled maintenance based on failurecharacteristics in operating context

– Design Changes

– Training improvements

– Operational changes

– One time changes

– Run to failure when cost effective and no

safety/environment concerns

RCM = less corrective maintenance

RCM = more proactive approach

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Marc Banghart

Functional Perspective

How do I keep

the pump

operating?

How do I keep

the tank full?

Traditional Maintenance Approach:

- Focused on the pump- Vibration Analysis etc.

- Minimize failures of the pump,

and determine maintenance strategy

A

Water Pumping System Example

Purpose:

Ensure proper fluid level in tank B, by

pumping fluid from tank A

B

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Marc Banghart

Why Functional?

• Traditional approach focused on keeping the pump

operational• Can other failures, besides pump failure cause the loss of

system function?

– Reservoir failure

– Hoses and fittings failure• What if the pump reliability cannot be improved, or

maintenance cannot be optimized?

• Alternate methods to ensure the system function is

preserved: – Pump redundancy (back-up pump)

– Gravity assisted flow

– Increased storage level in tank B (… buying time …)

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Where did RCM come from?

• Early PM assumed periodic overhauls ensured reliability

and safety – Especially prevalent in airline industry

– Based on the assumption that all equipment follow

“bathtub curve”

• Commercial airlines questioned reliance on overhauls in

1960’s due to rising costs, without more reliability

– Spurred by FAA assumption that new Boeing 747 PM

program would be three times larger than Boeing 707

(three times more passengers)

– Study launched to validate component failure

characteristics

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Airline Findings

11% 89%

5%

7%

14%

68%

2%

4%

A

B

C

D

E

F

FAILURE CHARACTERISTICS CURVES

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More about an Overhaul Philosophy

• What the airlines discovered

– Statistical analysis often showed no change in safety or reliability whenoverhaul limits changed…sometimes worsened

– Overhaul limits were usually not analytically based

– Overhauls generate high repair costs for little or no benefits

• Facts about overhauls – Many failure modes do not support overhaul philosophy - have no

“wear out” characteristic

– Considerable component life sacrificed

– Overhauls introduce infant mortality failures

Time

Overhaul intervalConditional

Probability

of Failure

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Post Study

• Study spurred development of conditioning monitoring

techniques• FAA and airlines established “Maintenance Steering Group

(MSG)” to investigate/recommend new approaches

– Initial Boeing 747 Customer Airlines and FAA

– Boeing manufacturing and support engineers• RCM developed and diverged into several “tracks”

• MSG (later coined RCM) applied the most appropriate

maintenance philosophy to each failure mode based on

data/information – Inspections

– Operate to Failure

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RCM Tracks

Early

PM

MSG-2

1970

MSG-1

1968

Nolan

Heap RCM

1978

MSG-3

1980

MSG-

3R1

1988

On-going

Updates

Space

Shuttle RCM

1980

NASA Facility

& GSE RCM

1988

Mil-Hdk-

266

1981

Mil-Std-

2173

1986

NAVAIR 403

Manual

1996

Commercial

1983

RCM IIMoubray

1992

RCM

Mac

Smith

1993

SAEStandards

1999

Hybrid

RCM

90’s

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What makes a process RCM?

• The seven SAE questions:

– What are the functions and associated desired standardsof performance of the assets in the present operation

context (functions)?

– In what ways can it fail to fulfill its functions (functional

failures)?

– What causes each functional failure (failure modes)?

– What happens when each failure occurs (failure effects)?

– In what way does each functional failure matter (failure

consequences)?

– What should be done to predict or prevent each failure

(proactive tasks and task intervals)?

– What should be done if a suitable proactive task cannot be

found (default actions)?

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Standards and References

• DoD Policy:

– “RCM shall be used as a logical decision process fordetermining optimum failure management strategies,

including maintenance approaches, and establishing the

need for both reactive and proactive maintenance tasks.”

• AFI 21-118

• AR 750-1

• MCO 4000.57A

• MIL-STD-3037

• NAVAIR 00-25-403• SAE JA 1011/1012

• DoD Manual 4151.22-M

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RCM in DoD

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RCM Process Flow (Navair)

PLANNING AND PREPARATION

ANALYSIS

IMPLEMENT RESULTS

SUSTAIN

FMECA

1. Identify Team and responsibilities

2. Identify analysis items3. Prioritize Items

4. Identify and document Review Process

5. Orientation/Training6. Ground Rules and Assumptions

1.Equipment Kick-off Meeting

2.Initial Data Gathering

3.Hardware Partition

4.Function

5.Functional Failure

6.Failure Mode

7.Failure Effects

8.Failure Consequences

9.Task Evaluation

10.Task Selection

SAE JA-1011

1. Package Maintenance Task

2. Implement Other Actions

1. Emergent Issues

2. Age Exploration

3. Hardware Changes

4. Trend/degrader analysis

5. Document Reviews

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PLANNING

ANDPREPARATION

PHASE

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Planning and Preparation

• Identifies and resolves issues that must be addressed prior

to beginning an analysis.

• Answers:

– Who

– What – In what order

– How

– With what resources

– When

• Culminates in Project Plan

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Project Plan

• RCM Projects should document the results of the planning

and preparation steps into an RCM Program Plan – Scope and size of plan is dependent on project

– Ensures consistency of analysis process

– Establishes priorities and schedule

–Documents contributions of team members andconcurrence by management

– Can be used for funding justification and to gain

management support

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Project Plan Elements

• RCM Program Plan Elements:

– Team and Responsibilities – Analysis scope

– Review and approval process

– Training Requirements

– Ground Rules and Assumptions – Sustaining task procedures

– Hazard Risk Matrix

– Metrics and Reporting requirements

– Funding requirements – Plan of action and milestones

– Contractor support requirements

– Deliverables

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Ground Rules and Assumptions

• A compilation of information required by RCM analysts to

perform analysis• Items included:

– Description of operating environment

– Standard operating procedures

– Data sources – Failure mode sources

– Analytical methods

– Cost-benefit analysis methods

– Default Values – Acceptable probability of failure

– Labor rates

– Equipment usage rates

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5 MINUTE BREAK

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Marc Banghart

ANALYSIS

PHASE

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Remember the Process….

• Analysis Steps:

– Equipment Kick-off Meeting

– Initial Data gathering

– Hardware Partitioning – FMECA

– Failure Consequences

– Task Evaluation

– Task Selection

Decision Logic

Not discussed further

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Hardware Partitioning

• A logical hierarchical division of an asset into progressively

lower levels to show relationships among systems,subsystems, components, etc.

– Also called EQUIPMENT HIERARCHY or HARDWARE

BREAKDOWN

• Partition may use any logical system:

– CMMS

– Work Unit Code

– Maintenance/Operators manuals

– OEM Parts breakdown

– Physical boundaries

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HW Partitioning Considerations/Suggestions

• Must be a physical partition:

– Each item should only be in one branch of the hierarchy – Consider how failure data is recorded

– Partition one level below where the analysis will be

performed

–Manuals may provide logical divisions of equipment

• Boundaries should be clearly identified:

– List specific valves, terminal blocks, etc. that end one

system and begin another

– Boundaries should take into consideration functions of

equipment

• Be prepared to adjust boundaries:

– During an analysis, better partitioning may become

evident, especially when defining functions

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Marc Banghart

Partitioning Example: Aircraft

FLT CONTROL

SYS 14000

AIRCRAFT1

LANDING GEAR

13000

FUEL SYSTEM

46000

CONTROL

RODS

14220

RUDDER

14230TRIM TAB

14240

SUBSYSTEM

1B2

RUDDER

SUB SYS

14200

SUBSYSTEM

1B4SUBSYSTEM

1B1

ACTUATOR

14210

TRIM

MOTOR

14250

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Marc Banghart

Partitioning Example: Power Plant

UNIT 2

N02

POWERPLANT

UNIT 1

N01

UNIT 3

N03

FLY ASH

N02NA

BED ASH

N02NB

BOILER

N02B

WASTE

SYSTEM

N02N

FUEL

N02F

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Marc Banghart

Partitioning Example: Air Compressor

PRESSURIZATION

SYSTEM 1B

INGERSOLL RAND

COMPRESSOR

SYSTEM

1A

SYSTEM

1C

COMPR

1B3B

CHK VALVE

1B3C

AIR FILTER

1B3D

SUBSYSTEM

1B2

AIR PUMP

ASSY 1B3

SUBSYSTEM

1B4

SUBSYSTEM

1B1

MOTOR

1B3A

PRESSURE

REG 1B3E

l

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Marc Banghart

Class Exercise

• Perform an End Item Hardware partition for your vehicle

• GR&A: – No specific make/model

– Use the following template

1st Level: End Item (Vehicle)2nd Level: Major Systems

3rd Level: Major Components

Use 5 minutes, group setting

Cl i S l i

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Marc Banghart

Class Exercise Solution

F il M d Eff d C i i li A l i

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Marc Banghart

Failure Mode, Effects and Criticality Analysis

• Process used to determine the functions, functional

failures, and failure modes of equipment; and theassociated effects, severity, and frequency of each failure

mode

• Steps involve identifying...

– Functions

– Functional Failures

– Failure Modes

– Failure Effects

– Severity of Failure effects

– Frequency of occurrence

FMEA

“C” in FMECA

D l i FMECA

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Marc Banghart

Developing a FMECA

• Failure Modes, Effects, and Criticality Analysis Identifies:

– Item – A description – Functions – What you want it to do

– Functional Failures – How it fails to do it

– Failure Modes – Why it fails to do it

– Failure Effects – What happens – Severity of Failure – How bad it is

– Failure Frequency – How often it happens

– Criticality – Severity + Frequency

FMECA Phil h

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Marc Banghart

FMECA Philosophy

• Function based on use not design capability

• Design capability > use to allow for degradation• Functional failure may be actual or defined

• Failure modes- physical failure

• Failure effects- what happens when failure occurs

– At the incident

– To the system

– To the asset

D l i F ti

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Developing Functions

• Primary function:

–The purpose for which the system or asset is acquired.

• Secondary functions

– Other functions that the system or asset may perform.

• Appearance

•Containment

• Control/ comfort

• Environmental/ economy/ efficiency

• Protective

• Transmission

• Safety/ structure/ superfluous

FMEA t FMECA C iti lit A l i

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Marc Banghart

FMEA to FMECA: Criticality Analysis

• Criticality assessment qualitative or quantitative

Failure Probability Levels (MIL –

STD –

882)

Description Level Individual Item Fleet

Frequent A Likely to occur in the life of the item Continuously experienced

Probable BWill occur several times in the life of an

itemWill occur frequently

Occasional CLikely to occur some time in the life of an

itemWill occur several times

Remote DUnlikely but possible to occur in the life of

an item

Unlikely, but can reasonably be

expected to occur

Improbable ESo unlikely, it can be assumed occurrence

may not be experiencedUnlikely to occur, but possible

Failure Mode Criticality, Cm : where

C iti lit C l l ti E l

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Marc Banghart

Criticality Calculation Example

Cl E i

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Marc Banghart

Class Exercise

Develop five functions the system for the hardware partition

you developed earlier.


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Marc Banghart


Functional Failures

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Marc Banghart

Functional Failures

• The ways in which a function fails

• May be more than one functional failure for a

function

• Can be defined as a point short of actual failure

Failure Modes

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Failure Modes

• The physical cause of the functional failure

• All reasonably likely failure modes listed

• Types of failure modes: – Deterioration

– Design problem

– Over stress

Failure Effects

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Marc Banghart

Failure Effects

• Describe what happens when a failure occurs

• Start at failure mode- Local Effect – What happens at the component that fails

• Describe effect on system or sub-system

– The idea is to keep asking “what happens next” until the

effect on the asset is reached

• Do not describe consequences (i.e. environmental,

safety, economics)

FMEA Example 1

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Marc Banghart

FMEA Example 1

Source NASA RCM Guide

FMEA Example 2

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Marc Banghart

FMEA Example 2

Source NASA RCM Guide

Class Exercise

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Class Exercise

• Develop two functional failures

• Develop three failure modes for one of the functionalfailures

• For each failure mode identify:

– Local failure effects

– System effects – End item effects


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Marc Banghart

5 MINUTE BREAK

Remember the Process

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Remember the Process….

• Analysis Steps:

–Equipment Kick-off Meeting

– Initial Data gathering

– Hardware Partitioning

– FMECA

–Failure Consequences

– Task Evaluation

– Task Selection

Decision Logic

Decision Logic

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Decision Logic

• Process used to determine what action should be taken to

eliminate or lessen the consequences that result from the

occurrence of a failure mode

RCM Process: RCM Task Evaluation

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RCM Process: RCM Task Evaluation

• Each Failure Mode reviewed to determine appropriate

failure management strategy:

– Consequence Categorization (Hidden or Evident,

Safety/Environmental or Economic/Operational impacts)

– PM Task selection (or No PM)

– Servicing

– Lubrication – On Condition

– Hard Time

– Failure Finding

– Age Exploration

– Other Action

RCM PM Tasks

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Marc Banghart

Servicing:

The replenishment of consumablematerials that are depleted during

normal operations.

RCM PM Tasks

RCM PM Tasks

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Marc Banghart

Lubrication:

The scheduled lubrication of a component (usually

based on the manufacture’s recommendations)

where the item’s design requires a non-permanent

lubricant for proper operation

RCM PM Tasks

RCM PM Tasks

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Marc Banghart

On-Condition

Periodic or continuous inspection

designed to detect a potential failure

condition prior to functional failure.

RCM PM Tasks

RCM PM Tasks

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Marc Banghart

Hard Time Task:

Scheduled

removal of an

item or arestorative action

at some specified

age limit to

prevent its

functional failure.

RCM PM Tasks

RCM Other Actions

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Marc Banghart

RCM Other Actions

• Usually a one time action, other than PM, that effectively

reduces consequences of failure or resolves problems

identified during the conduct of the analysis

• Examples:

– Item redesign

– Change in an operational or maintenance procedure

– Operating restrictions

– Training

– Publications

– Technology insertion

Class Exercise

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Marc Banghart

Class Exercise

• Choose one failure mode developed in the previous

exercise

• Utilize RCM decision logic (and document your rationale)

to identify:

– Is this a hidden or evident failure?

– What are the consequences of the failure

(safety/environmental)?

– Identify potential maintenance strategies that can be

used to mitigate the failure


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IMPLEMENT

RESULTSPHASE

Implement Results

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p

• When complete, the RCM analysis provides a list of

maintenance tasks and recommendations.

• In order to realize the benefits of these recommendations,

they need to be incorporated into a coherent and efficient

maintenance program.

• “Packaging” is the process of combining discrete

maintenance recommendations into a maintenance

program.

Task Packaging

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g g

• The result of an RCM analysis is a set of recommendations

for a series of discrete maintenance tasks.

• Task Packaging is the process of combining those discrete

tasks into an efficient, effective, and executable

maintenance program.

• Concurrent tasks combined into a set of “work packages”

• The objective is to minimize down-time and optimize useof resources

Concept of Work Packages

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p g

• A typical maintenance program is made up of Work

Packages based on common recurring units of measure:

• Calendar time

• Operating units

• Operating hours

• cycles

• production units

• A Combination of the above

Package Types: Examples

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Marc Banghart

g yp p

Calendar Packages:

• Daily

• Weekly

• 10, 14, 28, 30 days

• Monthly• Quarterly

• Semi-annually

• Yearly

• Etc.

Operating Unit Packages:

• Pre-start

• 10, 50, 100, 1000 hrs

• 1000, 3000, 10000 Miles

• 100 Landings

• 1,000 Rounds Fired• 10 Starts

• 10,000 units produced

• Etc.

Phased Maintenance

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• A set of recurring packages that allows work to be spread

out over several packages.

• Allows a more even distribution:

– Workload

– Resources – Down-time

Phased Maintenance Example

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p

• Phased Maintenance Example:

• Tasks 1,2,3 are performed every 100 hours

• Tasks 4,5 every 200 hours• Tasks 6,7,8,9 every 400 hours

Traditional packages would look like this:

100 hours: Tasks 1,2,3

200 hours: 1,2,3,4,5

300 hours: 1,2,3

400 hours: 1,2,3,4,5,6,7,8,9

(at 500 hours the 100 hour tasks start over)

Phased Packages might look like this:

100 hours: 1,2,3,4,6200 hours: 1,2,3,5,7

300 hours: 1,2,3,4,8

400 hours: 1,2,3,5,9

(at 500 hours the 100 hour tasks start over again)

Grouping … keep in mind

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p g p

• The prior discussion centered on grouping tasks as a result

of task frequency.

• There are many other factors that may influence the

decision to group tasks:

– Equipment location

– Equipment Complexity

– Trades/Skills required

– Availability of tools or parts required

– Down-time

– Elapsed Maintenance Time - Time required to complete

the tasks

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SUSTAINMENT

PHASE

RCM Sustainment

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• As with many other processes, a large part of the benefit of

RCM may be realized over time through a process of formal

monitoring and continuous improvement…

• Initial analysis may need update over time:

– Incorrect assumptions on initial analysis

– Hardware changes

– Unexpected failures

– Operating environment changes

RCM Sustainment (continued)

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• The objective of the sustainment process is to continually

monitor and optimize the current PM program to:

– Improve the overall efficiency and effectiveness of the

RCM and PM Program

• By:

– Deleting unnecessary requirements or adjusting intervals

– Identifying adverse failure trends

– Addressing new Failure Modes

– Recognizing the opportunity for insertion of new

maintenance procedures, techniques, design changes, and

tools

Sustaining Approaches

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• Continuous (Recommended)

– Fastest response to new issues

– RCM becomes a way of doing business

– Requires a “Champion”

•Periodic RCM Reviews

– May be preempted by “more important” issues

– Data/history may be lost between reviews

– May cause the sustainment effort to stagnate

–May require re-justification of resources

– Should only be used if resources do not permit continuous

sustainment

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EFFECTIVENESS OF RCM: AN

EXAMPLE FROM DOD

CH-47 Chinook Heavy Lift Helicopter

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• BEFORE RCM

– 200 Hour Phase maintenance

• AFTER RCM

– 400 Hour Cycle Service Plan

– 200 Hour Servicing/Inspection

• Number of Phase Maintenance tasks reduced by 73%

• Phase Maintenance requires 50% fewer man hours to

complete with an increase in readiness.

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Chinook Readiness Goals

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• RCM Implemented in 2004 … 75% FMC in Aug 2007 for

the first time

RCM and Condition Based Maintenance (CBM+)

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