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DISTRIBUTION A. Approved for public release: distribution unlimited. 11 USMC Reliability Centered Maintenance Version 1 / Feb 25, 2015 Mr. Del Bennie Marine.

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Presentation on theme: "DISTRIBUTION A. Approved for public release: distribution unlimited. 11 USMC Reliability Centered Maintenance Version 1 / Feb 25, 2015 Mr. Del Bennie Marine."— Presentation transcript:

1 DISTRIBUTION A. Approved for public release: distribution unlimited. 11 USMC Reliability Centered Maintenance Version 1 / Feb 25, 2015 Mr. Del Bennie Marine Corps Systems Command Acquisition Logistics and Product Support (ALPS) Research and Readiness Analysis Team Mr. Del 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 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 DISTRIBUTION A. Approved for public release: distribution unlimited. 33 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

4 DISTRIBUTION A. Approved for public release: distribution unlimited. 44 IOC BA 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 Decision PDR Proposed Integration (draft) (DOD 5000) RCM Analysis (Proposed) RCM Analysis/ Update (every years) (Proposed) RCM Analysis/ Update* * other potential trigger events (Proposed) RCM/Functional Analysis (Proposed) RCM Analysis/ Update (or as required) PoPS Gates Draft Process

5 DISTRIBUTION A. Approved for public release: distribution unlimited. 55 Proposed Integration (draft) IOC BA TMRRE&MDProd & DeplO&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 5

6 DISTRIBUTION A. Approved for public release: distribution unlimited. 66 Proposed Integration (draft) IOC BA TMRRE&MDProd & DeplO&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 6

7 DISTRIBUTION A. Approved for public release: distribution unlimited. 77 Proposed Integration (draft) IOC BA TMRRE&MDProd & DeplO&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. 7

8 DISTRIBUTION A. Approved for public release: distribution unlimited. 88 Proposed Integration (draft) IOC BA TMRRE&MDProd & DeplO&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. 8

9 DISTRIBUTION A. Approved for public release: distribution unlimited. 99 Proposed Integration (draft) IOC BA TMRRE&MDProd & DeplO&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 9

10 DISTRIBUTION A. Approved for public release: distribution unlimited. 10 MCSC RCM Analyses Process

11 DISTRIBUTION A. Approved for public release: distribution unlimited. 11 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

12 DISTRIBUTION A. Approved for public release: distribution unlimited. 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 RECENT PENDING

13 DISTRIBUTION A. Approved for public release: distribution unlimited. 13 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

14 DISTRIBUTION A. Approved for public release: distribution unlimited. 14 RCM SOE DST M&S 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 Integration

15 DISTRIBUTION A. Approved for public release: distribution unlimited. 15 RCM SOE DST M&S 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 I s a high-resolution modeling and simulation tool that enables detailed lifecycle predictions and quantifies risk & uncertainty What should/can happen Integration & Opportunities: Analysis Tools

16 DISTRIBUTION A. Approved for public release: distribution unlimited. 16 AAV RCM / Modeling & Simulation Integration -AAV FoV Analysis completed in February AAV PMCS Modeling & Simulation Analysis September 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 (A O ) - Mean Down Time (MDT) - Materiel Availability (A M ) RCM SOE DST M&S

17 DISTRIBUTION A. Approved for public release: distribution unlimited. 17 RCM Five Year Comparison 17 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 DISTRIBUTION A. Approved for public release: distribution unlimited. 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 DISTRIBUTION A. Approved for public release: distribution unlimited. 19 What's wrong? A design FMEA/FMECA is not synonymous with an RCM FMEA/FMECA ITEM FUNCTION FAILURE MODE CAUSEOP FAILURE EFFECT TITLE MODELOCALNEXT HIGHEREND EFFECTS DED 180DED 128DED 124DED 247DED 126DED 127DED : Rod EndTo provide a pivot point for the Balancer. To provide a fixing point for the Rod (item 102). Structural failureFatigueFiring/ 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 : GlandTo provide a housing for the seals and wear rings (items 204, 205, 206, 207 & 208). To cap the end of the Cylinder (item 101). Structural failureFatigueFiring/ Emplacement/ Displacement Leakage of N2 to atmosphere. No pressure in the system. No pressure to counterbalance the elevating mass. Unable to elevate or depress cannon. Stop firing. 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 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.

20 DISTRIBUTION A. Approved for public release: distribution unlimited. 20 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 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 ISO Depot Maintenance –Briefed Commander MARCORLOGCOM

24 DISTRIBUTION A. Approved for public release: distribution unlimited. 24

25 DISTRIBUTION A. Approved for public release: distribution unlimited. 25 ???


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