4CBM is a Maintenance Philosophy RCM Is the Hub of CBMCBM is a Maintenance PhilosophyRCM ProvidesRules of Evidence
5Proof of RCM Success: SHIPMER The processMaintenance analysis using RCM principlesExamines planned, preventive maintenance (PMS)Performed by In-Service Engineers (ISEs)SEA 04RM provides training and logistics supportProgress to dateSHIPMERs 1-54 completedNearly 90% of all O-Level PMS reviewedDocumented SURFMER savingsExceeded CNO goal of 30% reduction of maintenance manhoursAchieved nearly 50% reduction as of August 2006
6Road Map for applying CBM to Maintenance Tasks Step 4:Apply Rules for ApplicabilityTD: Life Renewal Replace/Restore)CD: Health MonitoringFF: Hidden Failure (Find/Repair)S/L: Servicing and LubricationIs the ExistingMaintenance Task Applicable?Task Does Satisfy Applicability RulesTask Does Not Satisfy Applicability RulesNoYesRedesignImprove task“Fix when failed”Determine/Classify Type TaskTIME- CONDITION- FAILURE- SERVICING LUBEDIR. DIR FINDING (S) (L)(TD) (CD) (FF)Step 3:APPLICABILITY(Second Filter)Restores or MaintainsOriginal ReliabilityIdentify Failure Mode(E.g., seized bearings)Step 1:AGE DEGRADATION(First Filter)Verify Requirement ExistsNoYesStep 2:Does a Significant Rate of Age Degradation Exist?No orAcceptably Slow Rateof DegradationSignificant RateNo taskStep 5:EFFECTIVENESS(Third Filter)Task Is Worth DoingIs the MaintenanceTask Effective?Apply Rules for EffectivenessSafety or the Environment (Law)Operational performance (Mission)All other failuresTask Does Satisfy Effectiveness RulesSchedule TaskTask Does Not Satisfy Effectiveness RulesNoYesExtend periodicitySample Vs 100% inspectionMake situationalRedesign taskSee other optionsStep 6:Improvement Option GoalsDevelop Recommendations for ChangeContinuous Improvement: periodicre-evaluation and adjustment of tasks
7Choosing CBM Technology Can’t afford it allWouldn’t all be worthwhile, anywayHow to choose?RCM is the key1. Determine what maintenance you need to do2. Find CBM technology to support it
8RCM Criteria for CBM-Enabling Technology Failures Happen: Dominant Failure ModesFailure mode is reasonably likely to occurApplicabilityMonitored parameter really correlates to the failure mode; andMeasures the parameter consistently and accurately; andMeasurements serve as an accurate indicator of required repair action; andThere is adequate time for corrective action before functional failure.
9RCM Criteria for CBM-Enabling Technology (cont.) EffectivenessSafety: Identifies repair threshold in time to reduce probability of failure to acceptable level; orMission: Identifies repair threshold in time to reduce risk of failure (probability times severity) to acceptable level; orEconomics: Identifies repair threshold in time to reduce cost to identify and prevent failure at less cost than repairing after run to failure.
10Other Considerations CBM does not eliminate the need for maintenance CBM technology has Ao and maintenance needsDeterioration may occur no matter what the maintenance approachGoal is to maintain or restore reliability at least costMay allow operator to secure an equipment before occurrence of disruptive and more costly failureCosts considered in determination of effectivenessHardware and software acquisitionDevelopment of operating procedures and parametric values vs. deterioration for monitored equipmentILS costs, including training
11Conclusions Application of CBM technology can be crucial to a successful CBM transitionBut only worthwhile technology should be appliedA CBM-enabling technology may be worthwhile only if:There is a specific failure mode that is reasonably likely to occurThe technology can accurately and consistently be used to predict the onset of the failure modeThe technology allows operators and maintainers to take appropriate action that reduces probability of failure (safety), risk of failure (mission), or cost of prevention to acceptable levelsThe technology “pays for itself” in terms of increased Ao or reduced maintenance costs.