Presentation on theme: "USMC Reliability Centered Maintenance"— Presentation transcript:
1 USMC Reliability Centered Maintenance Version 1 / Feb 25, 2015I 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 ProgramsI will present to you today an introduction to Reliability Centered MaintenanceTransition Lets take a quick look at the agenda………………………Mr. Del BennieMarine Corps Systems CommandAcquisition Logistics and Product Support (ALPS)Research and Readiness Analysis Team
2 USMC Policy / MCSC draft RCM Order MCSC RCM Proposed Integration AgendaUSMC Policy / MCSC draft RCM OrderMCSC RCM Proposed IntegrationMCSC RCM Analysis Process/ExecutionRecent and Pending RCM analysesNotable Analysis RecommendationsDST/RCM/M&S IntegrationOngoing ChallengesRecapQuestion and Answer period
3 MCO 4790.25 Ground Equipment Maintenance Program USMC RCM PolicyMCO Ground Equipment Maintenance ProgramPromulgated 12 Jan 2014Officially task MCSC to conduct RCMPer 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 OrderCurrently being routed to the various competencies prior to presentation to the Commander and Program Executive Officer Land Systems for concurrence and signatureThe order is planned to be subsumed by the MCSC Maintenance Planning and Management policyIAW 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 GEMPPer 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 ProcessProposed Integration (draft)IOCBATechnology Maturation & Risk ReductionEngineering & Manufacturing DevelopmentProduction & DeploymentSystems AcquisitionOperations & SupportCSustainmentFRPDecisionReviewFOCLRIP/IOT&ECDRPre-Systems AcquisitionMaterielSolutionAnalysisConceptPDRPoPSGates1234566666(every years)(Proposed)RCM Analysis/Update*(or as required)(DOD 5000)RCMAnalysis(Proposed)RCMAnalysis/Update(Proposed)RCM/FunctionalAnalysis(Proposed)RCM Analysis/UpdateThis 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 IOCBATMRRE&MDProd & DeplO&SCFRPDRFOCCDRMSAPDREarly FunctionalAnalysisChaired by Requirements Developer, supported by MCSCDefines System Functions and Functional Failures (performance parameters)Refines common understanding of operating contextSupports AoA activities and Alternate System Review (ASR)Supports refinement of ICD, Draft CDD and follow on RFPsOther potential triggers:Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc)ECPsUnanticipated failures/failure rates observedPQDRs
6 Proposed Integration (draft) Pre MS B RCM Analysis IOCBATMRRE&MDProd & DeplO&SCFRPDRFOCCDRMSAPDRPre MS B RCMAnalysisChaired 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 baselineSupports refinement of Draft CDD, including Sustainment KPP and Reliability and Ownership Cost KSAs as well as follow on RFPsOther potential triggers:Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc)ECPsUnanticipated failures/failure rates observedPQDRs
7 Proposed Integration (draft) Pre CDR RCM Analysis/Update IOCBATMRRE&MDProd & DeplO&SCFRPDRFOCCDRMSAPDRPre CDR RCMAnalysis/UpdateRefined 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 eventsSupports refinement of CPD (Sustainment KPP, Reliability and Ownership Cost KSAs) as well as follow on RFPsOut 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)ECPsUnanticipated failures/failure rates observedPQDRs
8 Proposed Integration (draft) Post MS-C RCM Analysis/Update IOCBATMRRE&MDProd & DeplO&SCFRPDRFOCCDRMSAPDRPost MS-C RCMAnalysis/UpdateConsiders results of product support demonstrations and Operational Tests/Field User Evaluations/Operator AssessmentsFinal 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)ECPsUnanticipated failures/failure rates observedPQDRs
9 Proposed Integration (draft) Iterative RCM Analyses/Updates IOCBATMRRE&MDProd & DeplO&SCFRPDRFOCCDRMSAPDRIterative RCMAnalyses/UpdatesEvery 3 – 5 years, or trigger eventCaptures updated configurations/ECPsAddresses observed failure trendsUpdates MTL/PMCS schedule as more system performance and reliability information becomes availableProvides feedback loop to the Warfighter and to theRequirements developers for similar/replacement systemsOther potential triggers:Change in Sustainment Strategy (CLS – Organic, PBL, PSI shift, etc)ECPsUnanticipated failures/failure rates observedPQDRs
10 MCSC RCM Analyses Process Research & Readiness AnalysisALPS& Program OfficeProgram OfficeLEGENDMCSC RCM ProcessV /26/14Analysis Requested1Requirement Validated2Establish Objectives & Boundary3Failure Mode Estimate45Analysis ApprovedRCM Review Group Requirements/ Responsibilities6AYesNoTechnical Documentation8Release ofNavalMessage7Developmentof Operating Context10Documentation Review9Review Group Read Ahead11Confirmation brief12BII- Analysis RequirementsI- Analysis DeterminationIII- Analysis PlanningOrientation/ Group Training13Phase 1: Information Phase14Consensus on Decisions16CDPhase 2: DecisionPhase15IV- RCM AnalysisProvide ILA DocumentationTechnicalAudit18Technically Correct19Min. 60 Daysprior to IVPublish Updated Analysis2122Recommendations ApprovedImplement Recommendations23RecordDisapproval Rationale25A Living ProgramAnalysisComplete17RCMAV- Audit PhaseAssignment to Logistics (PMCS, Tech manual, Training, process), Engineer (Design) IPT24SUSTAIN- Emergent Issues- Age Exploration- Hardware Changes- Trend/degrader analysis- Document ReviewsEVI- Implementation PhaseManagement Audit20Provide Feedback to R2A26Days
11 RCM Analyses Task Organized Review Group Marine MaintainerMarineOperatorEngineerProgram Officerep(s)SMEs as requiredHFESafetyEnvironmentalThermal EngrEtc.Task OrganizedRCM ReviewGroupTrained RCM Facilitator
12 Recent/Pending RCM Analyses Expeditionary Field Kitchen (EFK)Airtronic BurnerMulti-Band Radio II FoS (MBR II)Blue Force Tracker FoS (BFT)MK970 RefuelerAssault Amphibious Vehicle (AAV) Subsystems:AAV P7A1 Hull PMCSAAV Family Of Vehicles Deadline CriteriaWater Propulsion & Steering SystemsAAV Hydraulic SystemAAV Upgunned Weapon Station PMCSAAV Transmission/Suspension AnalysisAAV Engine/ Fuel SystemsAAV Upgunned WSAAV Hull electrical/ AFSSSLogistics Vehicle System Replacement (LVSR)Steering/SuspensionEngine/Fuel/Air/Exhaust/CoolingDrive Train/Transmission/Axle/TransferHydraulics Fans/LHS, WinchAir and Electrical System, CTIS, Backfit, and StorageMedium Tactical Vehicle Replacement (MTVR)MK 154 Mine Clearance LauncherAN/TPS-80 Ground/Air Task Oriented RadarM9 Armored Combat Earthmover
13 Notable Analysis Recommendations ProgramAnalysis RecommendationsAssault Amphibious Vehicle (AAV) PMCSRecommended the reduction of 70% of the PMCS tasks on the AAV platformAssault Amphibious Vehicle (AAV) Deadline CriteriaRecommended that operational checklists include new columns for deadline criteria and exceptions to non-useMulti-Band Radio II (MBR II)Recommended development of a mitigation strategy for HUB battery removal (bricking)Airtronic BurnerRecommended the transition to full organic support at significant cost savings to the USMCExpeditionary 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 InitiativeALPS intends to provide ProgramManagers within MCSC and PEO LS withsynergized RCM, failure analysis and predictive modeling and simulation (M&S) capabilities.This will enable Product Support decisions that maximize readiness and minimize cost.RCMSOEDSTM&SThis 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 SupportTool (SOE DST) The SOE DST is a web based application which utilizesUSMC data stored in the MDR in order to provide reliability andlifecycle trend analysisWhat has happened / is happeningM&S / DEMAND ProIs a high-resolution modeling and simulation tool that enables detailed lifecycle predictions and quantifies risk & uncertaintyWhat should/can happenRCMSOEDSTM&S
16 AAV RCM / Modeling & Simulation Integration AAV FoV Analysis completed in February 2014AAV PMCS Modeling & Simulation Analysis September 2013- Objectives:Evaluate the current impact of the RCM derived PMCS recommendationsEvaluate reliability changes due to RCM implementationConstruct and evaluate a high-resolution simulation to assess thelong-term impact of RCM derived PMCS modifications.Recommend possible modifications to RCM derived PMCS recommendations- MetricsPerformance of each alternative is evaluated with five primary metrics- Cost- Corrective Maintenance- Operational Availability (AO)- Mean Down Time (MDT)- Materiel Availability (AM)RCMSOEDSTM&S
17 RCM Five Year Comparison Pre-RCM11 checklists64:03:12 hours total if each checklist performed onceMany redundant tasksLimited compliance“Rainbow” Sheets: daily check of 68 tasks broken into groups, performed over 4-week periodPost-RCM15 checklists19:37:53 hours total if each checklist performed onceGreatly reduced redundancyGreater complianceEliminate unnecessary tasksDeadline criteria clearly defined
18 Ongoing Challenges Non-compliant RCM deliverables (SAE JA1011) Implementation of recommendations by PMOsLow demand signalMisunderstanding of what RCM achievesAccurate Failure Mode dataSME 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 auditedby AC ALPS RCM personnel. This has been a common theme throughout.ITEMFUNCTIONFAILURE MODECAUSEOPFAILURE EFFECTTITLEMODELOCALNEXT HIGHEREND EFFECTSDED 180DED 128DED 124DED 247DED 126DED 127DED 125001 : Rod EndTo provide a pivot point for the Balancer. To provide a fixing point for the Rod (item 102).Structural failureFatigueFiring/ Emplacement/ DisplacementRod 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).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 taskThe identified function's are the functionsof the piece parts and not that of the assetunder review required by RCMThe remaining analysis information is based on preventingthe loss of function of the piece parts instead of the assetunder review. This leads to a maintenance strategy thatdoes not support the tenets of RCM and therefore cannot belabeled RCMA design FMEA/FMECA is not synonymous with an RCM FMEA/FMECA
20 USMC Policy/MCSC Draft RCM Order MCSC RCM Proposed Integration RecapUSMC Policy/MCSC Draft RCM OrderMCSC RCM Proposed IntegrationMCSC RCM Analysis Process/ExecutionRecent and Pending RCM AnalysesNotable Analysis RecommendationsDST/RCM/M&S IntegrationOngoing ChallengesQuestion and Answer Period
21 Any Questions? Maj. Dustin Thorn 703-432-4022 Mr. Del Bennie Captain Chris RadelMr. Herbie MorrisAny Questions?