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USMC Reliability Centered Maintenance

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Presentation on theme: "USMC Reliability Centered Maintenance"— Presentation transcript:

1 USMC Reliability Centered Maintenance
Version 1 / Feb 25, 2015 I work as a Logistics Management Specialist at Marine Corps Systems Command in the Research and Readiness Analysis section of AC ALPS. My military background is in USMC Ground Ordnance Vehicle Maintenance. In my new position one of my primary duties is to facilitate RCM analyses for MCSC/PEO LS Programs I will present to you today an introduction to Reliability Centered Maintenance Transition Lets take a quick look at the agenda……………………… Mr. Del Bennie Marine Corps Systems Command Acquisition Logistics and Product Support (ALPS) Research and Readiness Analysis Team

2 USMC Policy / MCSC draft RCM Order MCSC RCM Proposed Integration
Agenda USMC Policy / MCSC draft RCM Order MCSC RCM Proposed Integration MCSC RCM Analysis Process/Execution Recent and Pending RCM analyses Notable Analysis Recommendations DST/RCM/M&S Integration Ongoing Challenges Recap Question and Answer period

3 MCO 4790.25 Ground Equipment Maintenance Program
USMC RCM Policy MCO Ground Equipment Maintenance Program Promulgated 12 Jan 2014 Officially task MCSC to conduct RCM Per MCO (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. MCSC draft interim RCM Order Currently being routed to the various competencies prior to presentation to the Commander and Program Executive Officer Land Systems for concurrence and signature The order is planned to be subsumed by the MCSC Maintenance Planning and Management policy IAW DoD Instruction CBM+ for Materiel Maintenance the Secretaries of the Military Departments and the Directors of the Defense Agencies shall: Require implementation of RCM and other appropriate reliability and maintainability analyses. As such HQMC I&L published the GEMP Per the Ground Equipment Maintenance Program (MCO ) MCSC and PEO LS are to use RCM analyses as a tool to support CBM+. CBM+ is the application and integration of appropriate processes, technologies, and knowledge-based capabilities to achieve the target availability, reliability, and operation and support costs of DoD systems and components across their life cycle. At its core, CBM+ is maintenance performed based on evidence of need, integrating RCM analysis with those enabling processes, technologies, and capabilities that enhance the readiness and maintenance effectiveness of DoD systems and components. CBM+ uses a systems engineering approach to collect data, enable analysis, and support the decision-making processes for system acquisition, modernization, sustainment, and operations. Total Productive Maintenance (TPM). TPM is a comprehensive approach to maintenance intended not only to prevent and correct equipment failures, but also to optimize equipment performance and extend equipment life cycle. In TPM, responsibility for maintenance extends throughout an organization, with operators and maintainers cooperating to predict, prevent, diagnose and correct equipment failures, and to provide feedback to improve maintenance plans and equipment design and modification to increase performance and reliability. Key Point is that RCM is a scientific process that should not be undertaken by an inexperience and untrained person. MCSC RCM facilitators go through a 10 day certification course and are then allowed to facilitate under the supervision of a trained RCM practitioner.

4 Proposed Integration (draft)
Draft Process Proposed Integration (draft) IOC B A Technology Maturation & Risk Reduction Engineering & Manufacturing Development Production & Deployment Systems Acquisition Operations & Support C Sustainment FRP Decision Review FOC LRIP/IOT&E CDR Pre-Systems Acquisition Materiel Solution Analysis Concept PDR PoPS Gates 1 2 3 4 5 6 6 6 6 6 (every years) (Proposed) RCM Analysis/ Update* (or as required) (DOD 5000) RCM Analysis (Proposed) RCM Analysis/ Update (Proposed) RCM/Functional Analysis (Proposed) RCM Analysis/ Update This illustrates that RCM is a living program that should be implemented early in the life cycle and repeated throughout the life cycle * other potential trigger events

5 Proposed Integration (draft) Early Functional Analysis
IOC B A TMRR E&MD Prod & Depl O&S C FRPDR FOC CDR MSA PDR Early Functional Analysis Chaired by Requirements Developer, supported by MCSC Defines System Functions and Functional Failures (performance parameters) Refines common understanding of operating context Supports AoA activities and Alternate System Review (ASR) Supports refinement of ICD, Draft CDD and follow on RFPs Other potential triggers: Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc) ECPs Unanticipated failures/failure rates observed PQDRs

6 Proposed Integration (draft) Pre MS B RCM Analysis
IOC B A TMRR E&MD Prod & Depl O&S C FRPDR FOC CDR MSA PDR Pre MS B RCM Analysis Chaired by MCSC (as are the remainder of the analyses) Initial FMECA, MTL/PMCS and system training developed (cursory knowledge of CIs) Best opportunity to recommend design changes that will enhance reliability prior to establishment of allocated baseline Supports refinement of Draft CDD, including Sustainment KPP and Reliability and Ownership Cost KSAs as well as follow on RFPs Other potential triggers: Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc) ECPs Unanticipated failures/failure rates observed PQDRs

7 Proposed Integration (draft) Pre CDR RCM Analysis/Update
IOC B A TMRR E&MD Prod & Depl O&S C FRPDR FOC CDR MSA PDR Pre CDR RCM Analysis/Update Refined FMECA, MTL and system training based on proposed configuration baseline (matured knowledge of CIs) Refined PMCS schedule and training to support Product Support Demos and additional DT/OT/FUE/OA events Supports refinement of CPD (Sustainment KPP, Reliability and Ownership Cost KSAs) as well as follow on RFPs Out of all of the pre-fielding analyses, this is the most critical due to the fidelity of system design information. Other potential triggers: Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc) ECPs Unanticipated failures/failure rates observed PQDRs

8 Proposed Integration (draft) Post MS-C RCM Analysis/Update
IOC B A TMRR E&MD Prod & Depl O&S C FRPDR FOC CDR MSA PDR Post MS-C RCM Analysis/Update Considers results of product support demonstrations and Operational Tests/Field User Evaluations/Operator Assessments Final refinement to overarching product support strategy, MTL, PMCS schedule, TMs, system training and related products prior to full rate production and fielding. Other potential triggers: Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc) ECPs Unanticipated failures/failure rates observed PQDRs

9 Proposed Integration (draft) Iterative RCM Analyses/Updates
IOC B A TMRR E&MD Prod & Depl O&S C FRPDR FOC CDR MSA PDR Iterative RCM Analyses/Updates Every 3 – 5 years, or trigger event Captures updated configurations/ECPs Addresses observed failure trends Updates MTL/PMCS schedule as more system performance and reliability information becomes available Provides feedback loop to the Warfighter and to the Requirements developers for similar/replacement systems Other potential triggers: Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc) ECPs Unanticipated failures/failure rates observed PQDRs

10 MCSC RCM Analyses Process
Research & Readiness Analysis ALPS & Program Office Program Office LEGEND MCSC RCM Process V /26/14 Analysis Requested 1 Requirement Validated 2 Establish Objectives & Boundary 3 Failure Mode Estimate 4 5 Analysis Approved RCM Review Group Requirements/ Responsibilities 6 A Yes No Technical Documentation 8 Release of Naval Message 7 Development of Operating Context 10 Documentation Review 9 Review Group Read Ahead 11 Confirmation brief 12 B II- Analysis Requirements I- Analysis Determination III- Analysis Planning Orientation/ Group Training 13 Phase 1: Information Phase 14 Consensus on Decisions 16 C D Phase 2: Decision Phase 15 IV- RCM Analysis Provide ILA Documentation Technical Audit 18 Technically Correct 19 Min. 60 Days prior to IV Publish Updated Analysis 21 22 Recommendations Approved Implement Recommendations 23 Record Disapproval Rationale 25 A Living Program Analysis Complete 17 RCMA V- Audit Phase Assignment to Logistics (PMCS, Tech manual, Training, process), Engineer (Design) IPT 24 SUSTAIN - Emergent Issues - Age Exploration - Hardware Changes - Trend/degrader analysis - Document Reviews E VI- Implementation Phase Management Audit 20 Provide Feedback to R2A 26 Days

11 RCM Analyses Task Organized Review Group
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

12 Recent/Pending RCM Analyses
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 Medium Tactical Vehicle Replacement (MTVR) MK 154 Mine Clearance Launcher AN/TPS-80 Ground/Air Task Oriented Radar M9 Armored Combat Earthmover

13 Notable Analysis Recommendations
Program Analysis 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.

14 RCM / SOE DST / M&S Integration
Predictive Modeling & Simulation applies advanced simulation technology to identify significant return on investment and to resolve asset management challenges. Pending Initiative ALPS intends to provide Program Managers within MCSC and PEO LS with synergized RCM, failure analysis and predictive modeling and simulation (M&S) capabilities. This will enable Product Support decisions that maximize readiness and minimize cost. RCM SOE DST M&S This best practice involves representing intrinsic system complexity in time dependent processes including equipment aging, system-wide interactions and the dynamic effects of operations and maintenance to enhance the resolution and accuracy of decision analyses.

15 Integration & Opportunities: Analysis Tools
RCM defines what must be done to a system to achieve the desired levels of safety, reliability, environmental soundness, and operational readiness, at best cost (DODI ). MCSC is currently conducting Reliability Centered Analyses utilizing a stand alone RCM approach however, efforts are underway to integrate the following analysis tools to further realize the benefits and power of RCM: Systems Operational Effectiveness Decision Support Tool (SOE DST) The SOE DST is a web based application which utilizes USMC data stored in the MDR in order to provide reliability and lifecycle trend analysis What has happened / is happening M&S / DEMAND Pro Is a high-resolution modeling and simulation tool that enables detailed lifecycle predictions and quantifies risk & uncertainty What should/can happen RCM SOE DST M&S

16 AAV RCM / Modeling & Simulation Integration
AAV FoV Analysis completed in February 2014 AAV PMCS Modeling & Simulation Analysis September 2013 - Objectives: Evaluate the current impact of the RCM derived PMCS recommendations Evaluate reliability changes due to RCM implementation Construct and evaluate a high-resolution simulation to assess the long-term impact of RCM derived PMCS modifications. Recommend possible modifications to RCM derived PMCS recommendations - Metrics Performance of each alternative is evaluated with five primary metrics - Cost - Corrective Maintenance - Operational Availability (AO) - Mean Down Time (MDT) - Materiel Availability (AM) RCM SOE DST M&S

17 RCM Five Year Comparison
Pre-RCM 11 checklists 64:03:12 hours total if each checklist performed once Many redundant tasks Limited compliance “Rainbow” Sheets: daily check of 68 tasks broken into groups, performed over 4-week period Post-RCM 15 checklists 19:37:53 hours total if each checklist performed once Greatly reduced redundancy Greater compliance Eliminate unnecessary tasks Deadline criteria clearly defined

18 Ongoing Challenges Non-compliant RCM deliverables (SAE JA1011)
Implementation of recommendations by PMOs Low demand signal Misunderstanding of what RCM achieves Accurate Failure Mode data SME support

19 A design FMEA/FMECA is not synonymous with an RCM FMEA/FMECA
What's wrong? This is an excerpt of one of many contract RCM deliverables tech audited by AC ALPS RCM personnel. This has been a common theme throughout. ITEM FUNCTION FAILURE MODE CAUSE OP FAILURE EFFECT TITLE MODE LOCAL NEXT HIGHER END EFFECTS DED 180 DED 128 DED 124 DED 247 DED 126 DED 127 DED 125 001 : Rod End To provide a pivot point for the Balancer. To provide a fixing point for the Rod (item 102). Structural failure Fatigue Firing/ Emplacement/ Displacement Rod becomes detached. Piston forced against Cylinder Eye. Loss of Balancer structural integrity. Cradle may become distorted. Minor instability results in potential minor injury. Unable to elevate or depress cannon. Stop firing. 002 : Gland To provide a housing for the seals and wear rings (items 204, 205, 206, 207 & 208). To cap the end of the Cylinder (item 101). Leakage of N2 to atmosphere. No pressure in the system. No pressure to counterbalance the elevating mass. - RCM is focused on maintaining the functionality of the asset not the piece parts - Design FMEA/FMECAs are not normally executed with the goal of developing an optimized PMCS strategy - Design FMEA/FMECAs are used to determine the critical failures in effort to design them out or develop corrective maintenance task The identified function's are the functions of the piece parts and not that of the asset under review required by RCM The remaining analysis information is based on preventing the loss of function of the piece parts instead of the asset under review. This leads to a maintenance strategy that does not support the tenets of RCM and therefore cannot be labeled RCM A design FMEA/FMECA is not synonymous with an RCM FMEA/FMECA

20 USMC Policy/MCSC Draft RCM Order MCSC RCM Proposed Integration
Recap USMC Policy/MCSC Draft RCM Order MCSC RCM Proposed Integration MCSC RCM Analysis Process/Execution Recent and Pending RCM Analyses Notable Analysis Recommendations DST/RCM/M&S Integration Ongoing Challenges Question and Answer Period

21 Any Questions? Maj. Dustin Thorn 703-432-4022 Mr. Del Bennie
Captain Chris Radel Mr. Herbie Morris Any Questions?

22 Backup Slides Backup Slides

23 RCM ISO Depot Maintenance
Briefed Commander MARCORLOGCOM


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