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

25. ???