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The Naval Sea Systems Command (NAVSEA) Reliability Centered Maintenance (RCM) & Condition Based Maintenance Plus (CBM+) Programs PRESENTED BY Marc Borkowski.

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Presentation on theme: "The Naval Sea Systems Command (NAVSEA) Reliability Centered Maintenance (RCM) & Condition Based Maintenance Plus (CBM+) Programs PRESENTED BY Marc Borkowski."— Presentation transcript:

1 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 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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. 2 Distribution Statement A: Approved for Public Release; Distribution Unlimited

3 NAVSEA Solving Fleet Maintenance Problems Distribution Statement A: Approved for Public Release; Distribution Unlimited 3

4 4 US NAVY Maintenance Policy (Highest Level) United States Constitution To provide and maintain a Navy (Article I, Section VIII) Distribution Statement A: Approved for Public Release; Distribution Unlimited

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6 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. Distribution Statement A: Approved for Public Release; Distribution Unlimited

7 RCM & CBM + Relationship 7 CBM is a Maintenance philosophy based on “evidence of need” RCM Provides Rules of Evidence RCM Provides Rules of Evidence Distribution Statement A: Approved for Public Release; Distribution Unlimited

8 NAVSEAINST RCM, CBM, CBM+ 2009, updated 2013 NAVSEAINST RCM, CBM, CBM+ 2009, updated 2013 DODI 4151.22 CBM+ 2007, updated 2012 DODI 4151.22 CBM+ 2007, updated 2012 8 History of RCM, CBM, & CBM+ at NAVSEA 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. Nowlan & Heap Reliability Centered Maintenance 1978 Nowlan & Heap Reliability Centered Maintenance 1978 NAVSEA MIL-P- 24534A 1985 NAVSEA MIL-P- 24534A 1985 Integrated Condition Assessment System (ICAS) 1995 SMARTSHIP RCM AND FLEETMER 1996 SMARTSHIP RCM AND FLEETMER 1996 OPNAV CBM POLICY 2007 (Now Updating) OPNAV CBM POLICY 2007 (Now Updating) MCM CBM & DS Study 2010 MCM CBM & DS Study 2010 MIL-STD 3034A 2014 MIL-STD 3034A 2014 Distribution Statement A: Approved for Public Release; Distribution Unlimited

9 NAVSEA RCM Goals & Processes RCM Goals: Develop cost effective maintenance procedures that preserve system functions Evaluate and standardize maintenance across platforms Continuous process improvement via FLEETMERs & RCM Workshops 9 RCM Processes: MIL-STD 3034A RCM – Step by step RCM Process – Available for use by all services DoD 4151.22M – 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) Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 10 https://assist.dla.mil Quicksearch= RCM Distribution Statement A: Approved for Public Release; Distribution Unlimited

11 RCM & CBM + Data Item Descriptions (DIDs) 1.DI-SESS-80991A Planned Maintenance System (PMS) Maintenance Requirement Card (MRC) 2.DI-SESS-80992A PMS Maintenance Index Page (MIP) 3.DI-MNTY-80990 PMS RCM Documentation Control Sheet 4.DI-SESS-80979A RCM Master System and Subsystem Index (MSSI) 5.DI-SESS-80980A RCM Failure Modes and Effects Analysis (FMEA) Report 6.DI-SESS-80981A RCM Functional Failure Analysis (FFA) Report 7.DI-SESS-80982A RCM Functionally Significant Item (FSI) Index 8.DI-SESS-80983A RCM Additional Functionally Significant Item (AFSI) Selection Report 9.DI-SESS-80984A RCM Logic Tree Analysis (LTA) with Supporting Rationale and Justification Report 10.DI-SESS-80985A RCM Servicing and Lubrication Analysis (SLA) Report 11.DI-SESS-80986A RCM Maintenance Requirement Index (MRI) 12.DI-SESS-80987A RCM Procedure Validation Report 13.DI-SESS-80988A RCM Task Definition Report 14.DI-SESS-80989A RCM Inactive Equipment Maintenance (IEM) Requirement Analysis Report 15.DI-SESS-80994A RCM Functional Block Diagram (FBD) 16.DI-SESS-81823A RCM Class Maintenance Plan (CMP) 17.DI-SESS-81829 RCM Corrective Maintenance (CM) Development Report 18.DI-MGMT-81915 Condition Based Maintenance Plus (CBM + ) Program Plan These DIDs are available on the DoD Assist website: http://quicksearch.dla.mil/ 11 Distribution Statement A: Approved for Public Release; Distribution Unlimited

12 12 Two RCM Processes Classic RCM Process Partitioning Interfaces FFA ID Functions FMEA Risk Management RCM Logic How accurate was FMEA? Does PM “Pay for Itself?” How well does PM work? Age Degradation Applicability Effectiveness Backfit RCM Process Continuous Improvement (MIL-STD 3034A) (MIL-STD-3034A) Distribution Statement A: Approved for Public Release; Distribution Unlimited

13 Backfit RCM Process 13 Distribution Statement A: Approved for Public Release; Distribution Unlimited

14 14 NAVSEA’s RCM Process Performing the right maintenance on the right equipment at the right interval maximizes A o and ROI 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) 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 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 15 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 16 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 17 Distribution Statement A: Approved for Public Release; Distribution Unlimited

18 RCM Certification at NAVSEA 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 18 NAVSEA provides: Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 (www.dau.mil) 19 Distribution Statement A: Approved for Public Release; Distribution Unlimited

20 FY15 NAVSEA Reliability Centered Maintenance Certification Training Schedule and Locations Indiana 4/13/15 Crane (NSWC) – L2 4/20/15 Crane (NSWC) – L1 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 Rhode Island 11/18/14 Newport (NUWC) – L1 5/5/15 Newport (NUWC) – L1 9/14/15 Newport (NUWC) – L2 Washington 3/16/15 Keyport (NUWC) – L2 3/23/15 Keyport (NUWC) – L1 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 (SPAWAR) – L2 Florida 12/8/14 Mayport (FLEETMER 81) – L1 1/26/15 Panama City (NSWC) – L2 2/2/15 Panama City (NSWC) – L1 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 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 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 FY15 RCM Certification Training Schedule promulgated NAVY msg: DTG 231742Z SEP 14 COMNAVSEASYSCOM Maryland 8/10/15 Baltimore (USCG) – L2 8/17/15 Baltimore (USCG) – L1 Hawaii 1/26/15 Pearl Harbor (FLEETMER 82) – L1 Distribution Statement A: Approved for Public Release; Distribution Unlimited 20

21 RCM & CBM + Policy The following policy documents require or govern the use of RCM, CBM and CBM + across DoD and Navy: DODI 4151.22 CBM + for Materiel Maintenance Capstone policy instruction that drives CBM + policy for NAVSEA. OPNAVINST 4790.16A (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 4700.7L (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 4790.4E (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 4790.27A (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. 21 Distribution Statement A: Approved for Public Release; Distribution Unlimited

22 What is CBM + ? 1.At its core, CBM+ is Condition Based Maintenance based on evidence of need provided by RCM analysis and other enabling processes and technologies. 2.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. 3.CBM+ uses sensors, data collection techniques, algorithms, and engineering analysis to provide applicable and effective maintenance requirements. CBM + Enables Affordable Life Cycle Maintenance 22 Distribution Statement A: Approved for Public Release; Distribution Unlimited

23 Evolution CBM + Enables Affordable Life Cycle Maintenance 23 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 24 Source: GAO Report 12-113 - January 2012 ARLEIGH BURKE DESTROYERS Additional Analysis and Oversight Required to Support the Navy’s Future Surface Combatant Plans Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 25 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 26 Distribution Statement A: Approved for Public Release; Distribution Unlimited

27 BACKUP SLIDES 27 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 28 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 29 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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 5000.2F – NAVSEAINST 5000.9A – OPNAVINST 4790.16B Document reviews in progress – Systems Engineering Plan (SEP) Guide – Technical Review Manual – SECNAVINST 5400.15C – SECNAV-M 5000.2 Template development – Draft 081 Maintenance Planning Specification template – Draft LCSP template – Draft BCA template 30 Distribution Statement A: Approved for Public Release; Distribution Unlimited

31 NAVSEA CBM+ Technology Metrics CBM+ Maturity Levels1/30/15 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. 0 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 Unknown30 Grand Total390 31 Distribution Statement A: Approved for Public Release; Distribution Unlimited

32 NAVSEA CBM+ Technology Metrics CBM+ Technology Details1/30/15 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 32 Distribution Statement A: Approved for Public Release; Distribution Unlimited

33 Source: Reliability-Centered Maintenance, Nowlan and Heap Operating age (time T) Inspection Interval Resistance to failure (R f ) B (Bearing temperature or vibration begins to increase) F (Bearing fails) TT ½(F-P) A (New bearing installed) 100% 0% CBM Example P (Bearing vibration reaches threshold) 33 Distribution Statement A: Approved for Public Release; Distribution Unlimited

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. 34 Distribution Statement A: Approved for Public Release; Distribution Unlimited

35 35 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. C PM < C R + C LC Distribution Statement A: Approved for Public Release; Distribution Unlimited


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