1. PRESENTED BY Marc Borkowski Ronald Graffius February 25, 2015
The Naval Sea Systems Command (NAVSEA) Reliability Centered Maintenance (RCM) & Condition Based Maintenance Plus (CBM+) Programs
PRESENTED BY
Marc Borkowski
Ronald Graffius
February 25, 2015
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2. BLUF
NAVSEA’s RCM methodology optimizes maintenance costs while maintaining inherent reliability of equipment and systems.
NAVSEA’s RCM training and certification program provides NAVSEA with a standard engineering analysis methodology for determining maintenance requirement tasks for Operational, Intermediate and Depot Level maintenance.
NAVSEA embraces advanced technology that reduce maintenance costs while increasing reliability through the use of sensor based technologies and prognostic health monitoring.
CBM+ builds upon Navy’s CBM strategy of performing maintenance based on the objective evidence of need.
NAVSEA plans to increase the use of CBM+ technologies where applicable and cost effective.
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3. Solving Fleet Maintenance Problems
NAVSEA
Solving Fleet Maintenance Problems
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4. US NAVY Maintenance Policy (Highest Level)
United States Constitution
To provide and maintain a Navy (Article I, Section VIII)
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6. What is RCM ?
RCM is a logical, structured process to determine optimal maintenance for any system or equipment.
“Optimal” includes risk management - safety (sailors), environment (law or regulations), mission and economics.
RCM applied throughout the life cycle enables continuous process improvement on maintenance actions.
RCM defines what must be done to achieve desired levels of safety and readiness at the best cost.
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7. RCM & CBM+ Relationship
CBM is a Maintenance philosophy based on “evidence of need”
RCM Provides
Rules of Evidence
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8. History of RCM, CBM, & CBM+ at NAVSEA NAVSEAINST DODI
Nowlan & Heap
Reliability Centered
Maintenance
1978
NAVSEAINST
RCM, CBM, CBM+ 2009, updated 2013
Integrated Condition Assessment System (ICAS) 1995
DODI
CBM+ 2007,
updated 2012
MIL-STD 3034A
2014
NAVSEA
MIL-P-
24534A
1985
SMARTSHIP RCM AND FLEETMER
1996
OPNAV
CBM POLICY
2007
(Now Updating)
MCM CBM
& DS Study
2010
RCM and CBM began with the Airline Industry in the 1970s and was adopted by NAVSEA soon after. CBM is the policy of how we maintain our ships today.
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9. NAVSEA RCM Goals & Processes
Develop cost effective maintenance procedures that preserve system functions
Evaluate and standardize maintenance across platforms
Continuous process improvement via FLEETMERs & RCM Workshops
RCM Processes:
MIL-STD 3034A RCM
Step by step RCM Process
Available for use by all services
DoD M
RCM program management
NAVSEA RCM Manual
Describes fundamentals of Level I and Level II RCM
Contract Data Requirements List (CDRL) and Data Item Description (DID) supported for Acquisition, Technology & Logistics (AT&L)
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10. MIL-STD 3034A “Reliability Centered Maintenance Process”
Updated and released in April 2014
Navy standard, but available to all services
12 phase fully detailed RCM process
Associated Data Item Descriptions (DIDs) for each phase
Quicksearch= RCM
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11. RCM & CBM+ Data Item Descriptions (DIDs)
DI-SESS-80991A Planned Maintenance System (PMS) Maintenance Requirement Card (MRC)
DI-SESS-80992A PMS Maintenance Index Page (MIP)
DI-MNTY PMS RCM Documentation Control Sheet
DI-SESS-80979A RCM Master System and Subsystem Index (MSSI)
DI-SESS-80980A RCM Failure Modes and Effects Analysis (FMEA) Report
DI-SESS-80981A RCM Functional Failure Analysis (FFA) Report
DI-SESS-80982A RCM Functionally Significant Item (FSI) Index
DI-SESS-80983A RCM Additional Functionally Significant Item (AFSI) Selection Report
DI-SESS-80984A RCM Logic Tree Analysis (LTA) with Supporting Rationale and Justification Report
DI-SESS-80985A RCM Servicing and Lubrication Analysis (SLA) Report
DI-SESS-80986A RCM Maintenance Requirement Index (MRI)
DI-SESS-80987A RCM Procedure Validation Report
DI-SESS-80988A RCM Task Definition Report
DI-SESS-80989A RCM Inactive Equipment Maintenance (IEM) Requirement Analysis Report
DI-SESS-80994A RCM Functional Block Diagram (FBD)
DI-SESS-81823A RCM Class Maintenance Plan (CMP)
DI-SESS RCM Corrective Maintenance (CM) Development Report
DI-MGMT Condition Based Maintenance Plus (CBM+) Program Plan
These DIDs are available on the DoD Assist website:
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12. Continuous Improvement
Two RCM Processes
Classic RCM Process
Partitioning
Interfaces
FFA
ID Functions
FMEA
Risk Management
RCM Logic
(MIL-STD 3034A)
Continuous Improvement
How accurate was FMEA?
Does PM “Pay for Itself?”
How well does PM work?
Age Degradation
Applicability
Effectiveness
Backfit RCM Process
(MIL-STD-3034A)
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13. Backfit RCM Process
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14. NAVSEA’s RCM Process Performing the right maintenance on the
right equipment at the right interval maximizes Ao and ROI
Performance
Best Manufacturing Practices Center of Excellence award 2007
Consistent, repeatable, auditable process for maintenance development
Evaluates systems at failure mode
Applies to Ships, Carriers & Submarines
Payoff
> 40% average maintenance manhour reduction since RCM enacted in 1997
Since 2001, over 9000 personnel RCM Certified
Additional savings in resources, asset management, logistics footprint and improved availability (collecting data for these metrics)
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15. MIL-STD 3034A Current Maintenance Development
NAVSEA early insertion of RCM in the acquisition process
DDG-1000 Zumwalt Class Destroyer
112 systems – RCM analyses conducted
CVN-78 Gerald R. Ford Class Carrier
22 new HM&E systems in progress
EM Catapults, Weps Elevators, Degaussing, etc.
Littoral Combat Ships (LCS) Freedom Class
85 systems – RCM analyses conducted
LCS Mission Modules RCM workshops
Ohio Class Replacement
Using RCM MIL-STD per contract
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16. RCM in Action Common Maintenance Planning WG
Improving Maintenance Requirements and Procedures across surface ships, submarines and carriers
Realize lowest possible cost over expected service life
Achieve required level of ship and equipment reliability
Provide required level of ship and personnel safety by:
Reviewing Maintenance Requirements and Procedures for Organizational, Intermediate and Depot Level Maintenance
Developing Common Assessment Procedures (CAPs)
Discovering best practices
Improving maintenance policy and processes
Identifying and adapting new technologies to solve maintenance problems
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17. RCM In Action Continuous Process Improvement
CMPWG Products
FLEETMER
RCM analysis of existing maintenance “Back-fit”
Broad cross enterprise look at multiple related systems
Prioritized using stakeholder input of high maintenance burdened systems
Common Maintenance Requirements Alignment MER
Deep dive study of one system or equipment across all ships and enterprises
Back to the basics area review of underlying technical rationale
Sweeping best practices research and evaluation
Flexible process with broad stakeholder involvement
NAVSEA RCM Classic Workshops
Classic RCM analysis
Narrowly focused deep look at specific equipment or component
Used across NAVSEA enterprise
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18. RCM Certification at NAVSEA
NAVSEA provides:
RCM Training & Certification Program
Level I – Basic fundamentals and “Backfit RCM” process
Two day course of instruction
Level II – “Classic RCM”
One week course of instruction
How to develop maintenance requirements
Level III – Train the trainer
Government only
Two week course of instruction
Level I and Level II plus experience
Required to re-certify annually
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19. RCM Certification RCM Training & Certification Program
Certifications are valid for three years
Recertification available online via electronic Planned Maintenance System Management Information System Gateway or classroom
Over 9000 students trained since inception in 2001
DAU RCM Training
Fundamentals of RCM (2 hour course)
DAU Continuous Learning Module CLL-030 (
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20. FY15 NAVSEA Reliability Centered Maintenance Certification Training Schedule and Locations
FY15 RCM Certification Training Schedule promulgated
NAVY msg: DTG Z SEP 14 COMNAVSEASYSCOM
New Hampshire
3/2/15 Dover (SUBMEPP) – L2
3/9/15 Dover (SUBMEPP) – L1
7/13/15 Portsmouth (FLEETMER 85)– L1
9/21/15 Dover (SUBMEPP) – L2
9/28/15 Dover (SUBMEPP) – L1
Pennsylvania
10/16/14 Philadelphia (NSWCCD) – L1
10/20/14 Philadelphia (NSWCCD) – L2
2/4/15 Philadelphia (NSWCCD)– L1
2/23/15 Mechanicsburg (NSLC) – L2
4/29/15 Philadelphia (NSWCCD) – L1
5/4/15 Philadelphia (NSWCCD) – L2
8/5/15 Philadelphia (NSWCCD) – L1
Washington
3/16/15 Keyport (NUWC) – L2
3/23/15 Keyport (NUWC) – L1
Indiana
4/13/15 Crane (NSWC) – L2
4/20/15 Crane (NSWC) – L1
Rhode Island
11/18/14 Newport (NUWC) – L1
5/5/15 Newport (NUWC) – L1
9/14/15 Newport (NUWC) – L2
California
11/6/14 San Diego
(SURFPAC) – L1
11/13/14 Port Hueneme
(NSWC PHD) – L1
3/9/15 San Diego
(SPAWAR) – L2
3/16/15 San Diego
(FLEETMER 83 )– L1
4/13/15 Port Hueneme
(NSWC PHD) – L2
4/20/15 Port Hueneme
(NSWC PHD) – L1
9/14/15 San Diego
(FLEETMER 86) – L1
9/21/15 San Diego
New Jersey
10/20/14 Lakehurst (NAVAIR) – L2
10/27/14 Lakehurst (NAVAIR) – L1
6/8/15 Picatinny Arsenal (NSWC) – L2
6/15/15 Picatinny Arsenal (NSWC) – L1
Maryland
8/10/15 Baltimore (USCG) – L2
8/17/15 Baltimore (USCG) – L1
Virginia
10/1/14 Norfolk (INSURV)– L1
10/6/14 Portsmouth (CPA) – L2
11/10/14 Suffolk (ISHPI) – L2
11/17/14 Fairfax (SEA04RM) – L2
12/17/14 Fairfax (SEA04RM) – L1
2/10/15 Fairfax (SEA04RM) – L1
4/20/15 Norfolk (SURFMEPP) – L2
5/11/15 Norfolk (FLEETMER 84) – L1
5/18/15 Fairfax (SEA04RM) – L2
7/6/15 Fairfax (SEA04RM) – L2
7/22/15 Fairfax (SEA04RM) – L1
8/10/15 Portsmouth (CPA) – L2
8/17/15 Portsmouth (CPA) – L1
8/24/15 Norfolk (NSLC) – L2
8/31/15 Norfolk (NSLC) – L1
Florida
12/8/14 Mayport (FLEETMER 81) – L1
1/26/15 Panama City (NSWC) – L2
2/2/15 Panama City (NSWC) – L1
Hawaii
1/26/15 Pearl Harbor (FLEETMER 82) – L1
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21. RCM & CBM+ Policy
The following policy documents require or govern the use of RCM, CBM and CBM+ across DoD and Navy:
DODI CBM+ for Materiel Maintenance
Capstone policy instruction that drives CBM+ policy for NAVSEA.
OPNAVINST A (Chief of Naval Operations CBM Policy)
Establishes policy and responsibility for the implementation and integration of Condition-Based Maintenance (CBM) for naval ship, submarine, aircraft systems, equipment and infrastructure.
OPNAVINST L (CNO Maintenance Policy for US Navy Ships)
Establishes maintenance policy for U.S. Navy ships and directs the common use of NAVSEA’s Reliability Centered Maintenance (RCM) methodology in developing maintenance require­ments.
OPNAVINST E (CNO Ships’ Maintenance & Materiel Management Policy)
Establishes policy and assigns responsibilities for the Ship’s 3-M System which is designed to provide for managing maintenance and maintenance support to achieve maximum equipment operation readiness.
NAVSEAINST A (NAVSEA RCM, CBM, & CBM+ Policy for Ships, Ship Systems and Equipment)
Aligns NAVSEA policy with DoD and OPNAV’s RCM, CBM and CBM+ policies, specifically, requiring RCM based maintenance and the establishment of a CBM+ Executive Steering Committee (Flag and SES level) and CBM+ Task Force (TF).
MIL-STD 3034A (Reliability Centered Maintenance (RCM) Process)
Delineates the 12 phase fully detailed RCM Process and includes the associated Data Item Descriptions (DIDs) for each phase. Appendix F describes relationships between RCM and CBM+. It is available for use by all Services.
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22. CBM+ Enables Affordable Life Cycle Maintenance
What is CBM+?
At its core, CBM+ is Condition Based Maintenance based on evidence of need provided by RCM analysis and other enabling processes and technologies.
CBM+ uses a systems engineering approach to collect data and enable analysis to support the decision-making processes for system acquisition, modernization, sustainment and operations.
CBM+ uses sensors, data collection techniques, algorithms, and engineering analysis to provide applicable and effective maintenance requirements.
CBM+ Enables Affordable Life Cycle Maintenance
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23. CBM+ Enables Affordable Life Cycle Maintenance
Evolution
CBM+ Enables Affordable Life Cycle Maintenance
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24. Why Should NAVSEA Implement CBM+?
At NAVSEA, ship maintenance and lifecycle sustainment are critical to the warfare enterprise.
NAVSEA expects to realize the following benefits from CBM+ implementation:
Improved Readiness and Availability of Ships
Metrics under development
TOC and MTBF are under analysis
Lower Lifecycle Maintenance Costs
CBM+ prevents high $ failures from occurring
BCAs must indicate that CBM $ over lifecycle pays off
Achieve Expected Service Life of Ships
The average cost of maintaining a Navy Destroyer over a 35 year lifecycle is over $65 Million per year, this is in addition to the ~ $2.6 Billion procurement cost for this ship
Source: GAO Report January 2012
ARLEIGH BURKE DESTROYERS
Additional Analysis and Oversight Required to Support the Navy’s Future Surface Combatant Plans
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25. Alignment to NAVSEA’s 2013-2018 Strategic Business Plan
CBM+ concepts and projects align to each of the Strategic Plan’s Mission Priorities
It’s all about the Ships
Improving ship maintenance using technology to predict failures
Reinvigorate shipboard preventive maintenance using NAVSEA’s RCM process to weed out ineffective maintenance tasks and fine tune remaining tasks
Improve warfighting system commonality by standardizing CBM+ top level requirements across the NAVSEA Enterprise
Technical Excellence and Judiciousness
Accelerate knowledge transfer by sharing the good and bad about our CBM+ projects
Increase knowledge management and improve maintainer competency through computer based training courses
Enforce budgetary judiciousness by ensuring that we are getting the most “bang-for-the buck” from our CBM+ technology investment
Culture of Affordability
Challenge every maintenance requirement--perform RCM analysis to determine applicability and effectiveness
Support Ship Characteristics Improvement Board decision making process by performing and thoroughly reviewing BCAs to determine cost benefits before buying technologies
Maximize commonality across platforms utilizing MIL-STD 3034A and DIDs for RCM and CBM+ in acquisition
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26. Benefits Improve Readiness and Availability of Assets
Improve equipment health to achieve Expected Service Life (ESL)
Maximize efficiency and reduce life-cycle maintenance costs through data-driven maintenance decisions
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27. BACKUP SLIDES
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28. ESC Goals Establish CBM+ as a priority within NAVSEA
Implement CBM+ policy across NAVSEA
Determine the status and maturity level of NAVSEA’s existing CBM+ technologies
Encourage use of proven cost effective CBM+ technologies
Encourage commonality to reduce variations when selecting CBM+ technologies
Remove barriers to CBM+ implementation
Identify and promulgate best practices while streamlining redundancies
Incorporate CBM+ in engineering design specifications, Systems Engineering Plans (SEPs), BCAs, Life Cycle Sustainment Plans (LCSPs), maintenance planning 081 specifications and sustainment KPPs and KSAs within CDDs and CPDs
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29. CBM+ Task Force Actions
The CBM+ Task Force (TF) will:
Determine the current state of CBM+ technologies being used in the Fleet
Data is being collected from each organization to aid in determining what we have today and capturing lessons learned
Determine maturity levels of existing systems
Explore cross enterprise, comprehensive end-to-end systems to take advantage of cost avoidance opportunities
Review systems in acquisition and modernization to ensure sensors are being installed and placed appropriately based on RCM analysis and failure modes that are trying to be prevented
Develop a common CBM+ BCA template for NAVSEA to be used by acquisition and modernization programs
Develop a common CBM+ LCSP template for NAVSEA to be used by acquisition and modernization programs
Develop a 081 Maintenance Planning Specification for NAVSEA to be used by acquisition and modernization programs
Determine what systems could benefit from CBM+ technologies
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30. CBM+ TF Accomplishments
Charters
ESC and TF charters have been developed
CBM+ Program Strategic Business Plan (SBP) and Plan of Actions & Milestones (POA&M)
Aligned to NAVSEA’s SBP and ESC goals
CBM+ Technology Matrix (living document)
Detailed questionnaire capturing key elements for all NAVSEA CBM+ technologies
Will be used for documenting the current state and identifying gaps and redundancies
Document reviews completed
JCIDS Manual
SECNAVINST F
NAVSEAINST A
OPNAVINST B
Document reviews in progress
Systems Engineering Plan (SEP) Guide
Technical Review Manual
SECNAVINST C
SECNAV-M
Template development
Draft 081 Maintenance Planning Specification template
Draft LCSP template
Draft BCA template
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31. NAVSEA CBM+ Technology Metrics
CBM+ Maturity Levels
1/30/15
0 - System identified for CBM+ consideration.
138
1- CBM+ Need Identified. RCM or FMEA analysis (relevant failure modes) done. 8
2- Technology concept or CBM application formulated. 35
3 – BCA has been completed that indicates that implementation of a CBM+ technology will lower life cycle maintenance cost.
4- CBM+ technology has been validated in a laboratory or relevant environment. 5
5- System or subsystem model or prototype has been demonstrated in a relevant shore based environment. 16
6 - System prototype has been demonstrated in an operational environment. 2
7 - CBM+ technology has been proven to work in its final form and under expected conditions. 32
8 - Actual system installed on platforms, and performing operationally under mission conditions.
124
Unknown 30
Grand Total
390
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32. NAVSEA CBM+ Technology Metrics
CBM+ Technology Details
1/30/15
Total Number of NAVSEA CBM+ Systems Identified
390
HM&E Systems
233
Combat Systems
157
Different generic sensor types (e.g. pressure switch, pressure transducer, RTD, thermocouple, position indicator, voltage, etc. ) 52
Technologies that answered “YES” to the following questions:
Are continuous failure probability predictions based on equipment conditions available? 42
Has a business case analysis (BCA) been performed?
117
Is there a capability to view ashore the same prognostic, diagnostic and maintenance information seen aboard ship? (i.e. Is data uploaded to a Distance Support Facility?)
133
Do distance support services avoid recurring cost licensing for this technology? (i.e. Government owns data rights to the technology (i.e. software))
145
Does the technology support Wide Area Network (WAN) reduced bandwidth?
114
Does analysis performed support an estimation of time to failure if no action is taken? 46
Is the diagnostic data used to determine equipment health?
204
Is/Has data from this technology being/been used to impact maintenance decisions?
190
Is a human machine interface (HMI) used by the crew to display equipment and system health information?
278
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33. CBM Example •
A (New bearing installed)
100% •
B (Bearing temperature or vibration begins to increase) •
P (Bearing vibration reaches threshold)
Resistance to failure (Rf) •
F (Bearing fails) 0% DT
Inspection Interval
½(F-P)
Operating age (time T)
Source: Reliability-Centered Maintenance, Nowlan and Heap
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34. Is a PM Task Applicable?
A task is applicable if it discovers, prevents, or reduces the impact of a failure mode identified through RCM analysis.
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35. CPM < CR + CLC Is a PM Task Effective?
A task is effective if it reduces the risk of the occurrence or economic impact of a failure to an acceptable level based on the consequences of failure.
If the cost of preventive maintenance is less than the cost of repair plus the cost of lost capability, performing the preventive maintenance task is cost effective.
CPM < CR + CLC
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