1. DISTRIBUTION A. Approved for public release: distribution unlimited. 11 Reliability Centered Maintenance Version 1 / Oct 29, 2014 Mr. Del “Treetop” Bennie Marine Corps Systems Command Acquisition Logistics and Product Support (ALPS) Research and Readiness Analysis Team Mr. Del “Treetop” Bennie Marine Corps Systems Command Acquisition Logistics and Product Support (ALPS) Research and Readiness Analysis Team

2. DISTRIBUTION A. Approved for public release: distribution unlimited. 22 Agenda Define Reliability Centered Maintenance Who Conducts RCM Analyses and Why Product Support Analysis (The Bigger Picture) History of RCM/Guiding Documents What Can RCM Achieve (WIIFM) Introduction/Overview of RCM  Traditional View of Failure  Reality of Failure  The Waddington Effect  Unwarranted Maintenance (Problem/Solution)  Outcomes of RCM process (proactive task and default actions) Recent RCM Efforts and Notable Analysis Recommendations Question and Answer Period

3. DISTRIBUTION A. Approved for public release: distribution unlimited. 33 What is Reliability Centered Maintenance? “RCM. A logical, structured process used to determine the optimal failure management strategies for any system, based on system reliability characteristics and the intended operating context. “ (DoDM 4151.22-M) “RCM. a process used to determine what must be done to ensure that any physical asset continues to do what its users want it to do in its present operating context. “ (Moubray) Doing the right maintenance, at the right time, for the right reason

4. DISTRIBUTION A. Approved for public release: distribution unlimited. 44 Who Conducts RCM and Why? Per MCO 4790.25 (GEMP) Commander, Marine Corps Systems Command (MARCORSYSCOM)/Program Executive Office (PEO) As the Marine Corps ground equipment asset (Class VII PEI) life cycle manager, develop, implement, document, assess, and refine program/product management strategies and maintenance support plans throughout materiel life cycle through RCM analysis to support CBM+ concepts and the performance of maintenance within a TPM strategy.

5. DISTRIBUTION A. Approved for public release: distribution unlimited. 55 PSA the Bigger Picture

6. DISTRIBUTION A. Approved for public release: distribution unlimited. 66 PSA Feeds Maintenance Planning

7. DISTRIBUTION A. Approved for public release: distribution unlimited. 77 Studied RCM Competitive Selection Self-sufficiency (PM-AAA) 2008 – GDAMS institutionalized AAAV/EFV 1999 History of RCM Nowlan & Heap 1978 MCO 4700.3 1984 Based on existing MSG process No training Cancelled circa 1985/86 HQMC/MCSC 2004 In-House capability attempted HQMC advocate - funded Logistics – then Engineering managed Contractor reliant Not institutionalized MCSC 2010 RCM billets created RCM Process IPT formed RCM Process developed DoDI 4151.22 DoD 4151.22-M Program Cancelled 2011 MCO 4790.25 GEMP 12 Jan 2014 JPO MRAP ~2008

8. DISTRIBUTION A. Approved for public release: distribution unlimited. 88 What Can RCM Achieve? (WIIFM) Optimized Maintenance Strategy Maintenance Effectiveness and Efficiency Higher Achievement of Inherent Reliability and Availability Greater Safety and Environmental Integrity Improved Product Quality Longer Useful Life of Expensive Items Design Improvements A Maintenance Database and increased knowledge of your systems Typically Reduces Maintenance Man-Hours, Logistics Footprint, and Total Ownership Cost Ownership of the maintenance strategy

9. The “traditional view” of failure is based on the notion that everything has a “life” and most failures are age related and that periodic maintenance will improve reliability. Maintenance interval ConditionalProbability of Failure “Age” (Miles/Hours/Rounds/Days/Cycles etc.) "LIFE" The “Traditional View” of FailureWear-OutZone Random Failure

10. The Reality of Failure A C D E F 4% 2% 5% 7% 14% 68% 11% 89% “Reliability Centered Maintenance” 1978 Nolan and Heap for the U.S. DoD B LIFE Random Failure patterns reflecting NO RELATIONSHIP TO AGE Based on several industry and DoD studies, the vast majority of components do not exhibit a life.

11. The Waddington Effect (c. 1943) Flying hours since last scheduled maintenance 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 Scheduled Maintenance * Dr. Jim Ignizio University of Texas, 2010 Unscheduled maintenance per 10 flight hours 11 Dr. Waddington discovered that B-24s were failing at a higher rate just after scheduled maintenance. As failures would taper off over time, scheduled maintenance was resulting in the destabilization of an otherwise stable system.

12. D E F 10 20 30 40 50 A B C “If it ain’t broke, fix it till it is” 12 The Waddington Effect (c. 1943) For components that exhibit a life, scheduled maintenance makes sense. For components that do not exhibit a life, scheduled maintenance is UNWARRANTED and can be a waste of resources and even damaging.

13. Unwarranted Maintenance  Unwarranted maintenance tasks will result in: Decreased asset availability High repair costs with little or no benefit Maintenance-induced failures No change in safety or reliability A considerable loss in component life 13

14.  Unwarranted maintenance tasks will result in: Decreased asset availability High repair costs with little or no benefit Maintenance-induced failures No change in safety or reliability A considerable loss in component life  Unwarranted maintenance tasks can be the result of: Maintenance program developed outside the RCM methodology Developed by the OEM Borrowed from similar equipment “This is the way we’ve always done it” “Good idea” maintenance 14 Unwarranted Maintenance Evidence of Need  RCM identifies alternatives to such tasks & applies the most appropriate maintenance approach based on the “Evidence of Need”. Solution

15. A scientific process used to determine what must be done to ensure that any system continues to do what its users want it to do in its present operating context: 1.What are the functions (or purpose) of the system?  Identify Functions 2. In what ways can the system fail?  Identify Functional Failures 3. What causes the system to fail?  Identify Failure Modes 4. What happens when the system fails?  Identify Failure Effects 5. Does it matter if the system fails?  Identify Failure Consequences 6. Can anything be done to predict or prevent the failure?  Identify proactive tasks 7. What if the failure cannot be predicted or prevented?  Identify default tasks Phase 1: Information Phase Phase 2: DecisionPhase RCM Questions

16. DISTRIBUTION A. Approved for public release: distribution unlimited. 16 RCM Analysis Outputs Proactive Tasks: Scheduled tasks designed to anticipate or prevent failures. - On condition tasks (CBM) - Scheduled Maintenance: (aka “Hard Time”) Rebuild / Overhaul Replacement - Lubrication/Service Default Actions: Actions taken if a proactive task cannot be found. - Failure Finding - Walk-around inspections - Age exploration - Redesign - Run to failure

17. DISTRIBUTION A. Approved for public release: distribution unlimited. 17 Your Involvement Operator and Maintainer SME support for RCM analyses 100% implementation/execution of PMCS as prescribed by technical documentation Accurate data collection and reporting Feedback to PMO for continuous process improvement Patience…it takes time to turn a ship around

18. DISTRIBUTION A. Approved for public release: distribution unlimited. 18  Expeditionary Field Kitchen (EFK)  Airtronic Burner  Multi-Band Radio II FoS (MBR II)  Blue Force Tracker FoS (BFT)  MK970 Refueler  Assault Amphibious Vehicle (AAV) Subsystems: –AAV P7A1 Hull PMCS –AAV Family Of Vehicles Deadline Criteria –Water Propulsion & Steering Systems –AAV Hydraulic System –AAV Upgunned Weapon Station PMCS –AAV Transmission/Suspension Analysis –AAV Engine/ Fuel Systems –AAV Upgunned WS –AAV Hull electrical/ AFSSS  Logistics Vehicle System Replacement (LVSR) –Steering/Suspension –Engine/Fuel/Air/Exhaust/Cooling –Drive Train/Transmission/Axle/Transfer –Hydraulics Fans/LHS, Winch –Air and Electrical System, CTIS, Backfit, and Storage Recent RCM Analyses

19. DISTRIBUTION A. Approved for public release: distribution unlimited. 19 ProgramAnalysis Recommendations Assault Amphibious Vehicle (AAV) PMCS Recommended the reduction of 70% of the PMCS tasks on the AAV platform Assault Amphibious Vehicle (AAV) Deadline Criteria Recommended that operational checklists include new columns for deadline criteria and exceptions to non-use Multi-Band Radio II (MBR II) Recommended development of a mitigation strategy for HUB battery removal (bricking) Airtronic Burner Recommended the transition to full organic support at significant cost savings to the USMC Expeditionary Field Kitchen (EFK) Recommended the reevaluation of the upper temperature operating limit contained in MIL STD 810G (120 degrees F) Blue Force Tracker (BFT) Recommendation to investigate a possible redesign to incorporate a software change. If this software change and other recommendations were to be incorporated, the projected 10-year cost decrease to the BFT FoS would reflect a decrease of $464,773 in material costs and a net decrease of 4,863,072 maintenance man-hours at all maintenance levels. Notable Analysis Recommendations

20. DISTRIBUTION A. Approved for public release: distribution unlimited. 20 Recap Define Reliability Centered Maintenance Who Conducts RCM Analyses PSA (The Bigger Picture) History of RCM/Guiding Documents What Can RCM Achieve (WIIFM) Introduction/Overview of RCM  Traditional View of Failure  Reality of Failure  The Waddington Effect  Unwarranted Maintenance (Problem/Solution)  Outcomes of RCM process (proactive task and default actions) Recent RCM Efforts and Notable Analysis Recommendations

21. DISTRIBUTION A. Approved for public release: distribution unlimited. 21 Any Questions?

22. DISTRIBUTION A. Approved for public release: distribution unlimited. 22 Backup Slides

23. DISTRIBUTION A. Approved for public release: distribution unlimited. 23 RCM Implementation within the Acquisition Process Implementation

24. DISTRIBUTION A. Approved for public release: distribution unlimited. 24 IOC BA Technology Development Engineering & Manufacturing Development Production & Deployment Systems Acquisition Operations & Support C Sustainment FRP Decision Review FOC LRIP/IOT&E CDR Pre-Systems Acquisition Concept Refinement Concept Decision PDR Proposed Process (draft) (DOD 5000) RCM Analysis (Proposed) RCM Analysis/ Update (every 3 - 5 years) (Proposed) RCM Analysis/ Update* * other potential trigger events (Proposed) RCM/Functional Analysis (Proposed) RCM Analysis/ Update (or as required) 1234566666 PoPS Gates Draft Process

25. DISTRIBUTION A. Approved for public release: distribution unlimited. 25 MCSC RCM Analyses Process

26. DISTRIBUTION A. Approved for public release: distribution unlimited. 26 Marine Maintainer Marine Operator Engineer Program Office rep(s) SMEs as required HFE Safety Environmental Thermal Engr Etc. Task Organized RCM Review Group Trained RCM Facilitator RCM Analyses Task Organized Review Group