RCM to CBM from Platform To Enterprise AMG2CC Conference RCM to CBM from Platform To Enterprise 25 February 2015 Jeff Banks Complex System Monitoring Department Head jcb242@psu.edu (814) 863-3859 Bob Walter Applied Enterprise Systems Department Head rlw9@psu.edu (814) 863-8876

University Affiliated Research Center (UARC) Established in 1945 by the Navy post WW II Technology Areas Undersea Weapons Comms and Information Undersea Vehicles Power and Energy Hydrodynamics and Structures Navigation Acoustics & Quieting Materials/ Manufacture S&T Largest Interdisciplinary Research Unit at Penn State – 1205 faculty/engineers, staff, students Classified facilities and programs Designated an University Affiliated Research Center by DoD in 1996 “…maintains a special long-term strategic relationship with DoD for technology development and engineering applications.” 2

ARL Penn State Mission Serve as a university center of research excellence and advanced capabilities for critical DoD sciences and technology and related applications. Champion the transition of advanced technology to operational systems in support of DoD acquisition programs, legacy platforms and the defense industry. Contribute to the education, research, and service mission of The Pennsylvania State University VIRGINIA CLASS ARMORED AND TACTICAL VEHICLES STUDENT PHOTO

Trusted Agent Support RCM Analysis & CBM+ Technologies U.S. Army Ground Combat Systems U.S. Marine Corps Motor Transport and LAV U.S. Army Tactical Wheeled Vehicles U.S. Navy Submarines U.S. Navy Surface Fleet Prototype Systems RCM Analysis & CBM+ Technologies

TACOM CBM+ Fleet Management Dashboard Vehicle Serial No. Oil Analysis Location Unit Maintenance History Family Operational History Fleet Web-based, Fleet Management application enabling reporting, searching, filtering, data downloading across multiple data sources. Vehicle Sensor and Health Developed by VENCORE for the U.S. Army: https://isg.vencore.com/TACOM/

Maintenance Management CBM+ Example https://army-cbmplus.sil.arl.psu.edu/StrykerPortal/

History of Maintenance Methodologies Ref: Handbook – "Operating Equipment Asset Management – Your 21st Century Competitive Necessity" First Edition

Reactive Maintenance Reactive Maintenance is corrective action applied on failure or obvious, unanticipated threat of failure: run-to-failure. Run-to-failure is simplistic, requires no forethought, and, at least up to the point of equipment failure, appears to require the least support. An unexpected failure can endanger personnel; releases toxic, flammable or polluting material; interrupts production; and/or causes collateral damage. Reactive maintenance does make economic sense in some cases (replacing easily accessible light bulbs, fuses) but the decision to implement reactive maintenance must be based on probability, cost, and consequences.

Preventive Maintenance (PM) Preventative Maintenance tasks include inspection, service and/or replacement conducted at regular, scheduled intervals. Established to avoid failure based on average statistical/anticipated lifetime. PM may be invasive, requiring an outage and disassembly for visual inspection and/or overhaul/replacement regardless of condition. The intervals between specific Preventive Maintenance tasks are based on average life. A PM program can be cost effective when equipment operation is consistent, average life is predictable within a reasonable span, failures are well understood, and useful failure statistics are available.

Preventative Maintenance Checks and Services (PMCS) PMCS is  a structured method of maintaining a piece of equipment in a fully mission capable condition so that it is mission ready when needed. Designated Intervals. PMCS is conducted at specific time throughout your use of the equipment.  The following intervals are specified for PMCS under normal conditions: BEFORE checks and services of PREVENTIVE MAINTENANCE must be performed prior to placing vehicle or its components in operation. DURING checks and services of PREVENTIVE MAINTENANCE must be performed while the vehicle and/or its components/systems are in operation. AFTER checks and services of PREVENTIVE MAINTENANCE are performed upon completion of mission. WEEKLY checks and services of PREVENTIVE MAINTENANCE are performed once every 7 days. MONTHLY checks and services of PREVENTIVE MAINTENANCE are performed once every 30 days. http://www.ut.ngb.army.mil/141mi/Warrior%20Webpages/Driver%27s%20Training/Lesson%205.htm

Preventative Maintenance: Assumptions Correlation between age and/or usage and failure rate. Increased Age or Usage = Increased Probability of Failure? For many systems and components this assumption is not valid.

Predictive (PdM) or Condition Based Maintenance (CBM) PdM/CBM: Maintenance action based on actual condition obtained from in-situ, non-invasive tests, operating and condition measurements. Condition Based Maintenance has proven capable of identifying faults early enough to minimize the impact of: operational interruptions avoid expensive failures including collateral damage significantly reduce the cost of maintenance Some potential failures, such as fatigue, are not easily detected with condition measurements.

Condition Based Maintenance Condition measurement consists of non-invasive measurements that define mechanical and operating condition Measurements may be made continuously (on-line) from installed transducers or periodically with portable equipment. Condition monitoring and (health) assessment is the individual and collective comparison of condition measurements, value versus time trends to arrive at an appraisal of current condition, identify and analyze defects (diagnostics). Condition assessment is also directed at detecting and identifying degradation mechanisms. 3. Repair and Maintenance actions based on condition monitoring and health assessment—the objective evidence of need. OPERATING EQUIPMENT ASSET MANAGEMENT  YOUR 21ST CENTURY COMPETITIVE NECESSITY, By John S. Mitchell

P-F Interval “The interval between the occurrence of a potential failure and its decay into a functional failure” Point where failure starts to occur Vibration Analysis Detection Oil Analysis Detection Temperature Detection Audible Noise Detection Condition If the P-F interval is too short, PT&I technology may not be effective. Time Functional Failure Reliability-centred Maintenace , by John Moubray

CBM Terminology Diagnostic Capability: the ability to detect and isolate a failure to a specific platform component or system. Predictive Capability: the ability to detect and isolate a fault to a specific platform component or system while the system is still functional. Prognostic Capability: the ability to detect and isolate a fault to a specific platform component or system while the system is still functional and the ability to determine the remaining useful life (RUL) until failure.

Comprehensive Maintenance Practitioners recognize that a comprehensive equipment management strategy will include a blend of: Reactive Maintenance Preventive Maintenance Condition-Based Maintenance to be applied based on the specific circumstances, probability, and consequences (risk) of failure.

The RCM Process How to best design a maintenance management strategy for your assets or platforms? Which methodologies will allow for the most effective and efficient operation and maintenance of each asset. The Reliability Centered Maintenance process is used to determine which type or combination of maintenance methodologies is most appropriate and effective for operating a highly reliable and productive assets and platforms.

The Major Elements of the Basic RCM Process RCM Establishment and Planning Analysis: Define the function and functional failures of a specific platform, system or component. Then conduct a Failure Modes and Effects Analysis Identify the failure consequences Determine maintenance tasks and intervals. Analysis Audit Implementation Sustaining the RCM Program: RCM is a ‘Living Program’ Implement a RCM management, training, benchmarking, and review process to provide feedback and measurement of progress toward asset management goals SAE JA1011/1012 and TACOM ILSC CBM+, Reliability Centered Maintenance Process Overview

Steps for the RCM Analysis Process: Information and Decision Identify System Functions: What does the user need the system to do in its current operating context? Identify Functional Failures: In what way can the system fail (or fail to fulfill its function)? Identify the Failure Modes: What causes the failures? Identify the Failure Effects: What happens when failures occur and what are the symptoms of failure? Identify Failure Consequences: How and why does the failure matter. Frequency of occurrence Severity of the failure mode Determine Maintenance Tasks and Intervals: Can the failure be predicted or prevented? Identify Other Logical Actions: What can be done if the failure cannot be predicted or prevented? Reference: SAE JA1011/1012 and TACOM ILSC CBM+, Reliability Centered Maintenance Process Overview

Platform Degrader Analysis: RCM/CBM/BCA The first fundamental concept is that it may not be cost effective to implement health management technology for the entire platform, so where should it be implemented? In general, embedded diagnostic and predictive technologies can have the greatest impact on reducing maintenance activities and increasing platform operational availability when it meets three requirements: Maintainability: Identify Critical Components with Fault Detection/ Isolation Challenges Reliability: Identify Critical Components with High Failure Rates and Costs Identify High Probability of Occurrence Failure Modes of Critical Components Identify Sensors, Monitoring Hardware and Processes to Enable Diagnostic and/or Predictive Capabilities Develop Cost Benefit Analysis Model using Degrader Results to Identify Most Cost Effective Health Management Design Logistic: Identify Critical Components with Significant Logistic Delay and Repair Times Relatively high failure rates Significant maintainability issues Highly critical components

Platform Degrader Data Sources 1. Vehicle Part Replacement Data 2. Maintainer Interviews Provides insight into existing system capability and criticality. Provides a statistical based assessment of component failure rate. 3. OEM Questionnaire Provides an indication of maintainability and troubleshooting issues.

Platform Degrader Analysis – Systems for Focus The results of the degrader analysis include a list of components and sub-systems that contribute most to maintainability, reliability and vehicle operational availability issues. When a component or sub-system ranked significantly high in each of the three data sources, then it was considered a top vehicle degrader.

Platform Degrader – Potential VHMS Solutions This phase of the analysis involves identifying failure modes and sensors that could be utilized to enable a diagnostic and predictive capability for each degrader system or component This analysis provides a recommended list of sensors that either currently exist on the platform or would need to be added to monitor for each identified failure mode.

Platform Degrader Potential Solutions For this fuel system, it was determined based on the criticality portion of the analysis that three of the eleven could be considered ‘high criticality’ failure modes that are candidates for CBM. Critical: PT Fuel Pump, In-Tank fuel Pumps Non-Critical: Fuel Filter The health coverage column provides an approximate indication of the percentage of the failure modes/mechanisms that each VHMS capability could detect.

Trade Space Populated with Every Design Configuration CBA Trade Study Model RCM/Degrader Analysis Components and Systems Failure Modes Quantity/Type of Sensors Diagnostic Capability Predictive Capability Health Management Design Configurator Generates every possible combination of design options described by the degrader analysis Cost Model On-platform HW/SW Off-Platform Enterprise Architecture Publications/Training Benefit Model Monetary Benefits Reduced parts due to decreased misdiagnosis Non-Monetary Benefits Increase in operational availability Trade Space Populated with Every Design Configuration ROI, B/C Ratio Acquisition and Sustainment Costs

Decision Phase: CBA Trade Study Analysis The final phase of the analysis involves evaluating the results from the CBA trade study model for decision making. The tool provides the ability to vary the axis combinations: Ao, Cost and HMS level Each object is one platform implementation option.

Ao & ROI & Total Cost Reduction & Acquisition Pareto 1:Optimized VHMS for ROI 2 & 3: Optimized VHMS for ROI and Ao 4: Optimized VHMS for Ao

Business Case Analysis: Decision Metrics by Subsystem The intention of this chart is to show the relative benefit for the implementation of CBM solutions for non-electronic LRU’s and the fact that every system should not have CBM implemented.

Summary – RCM and CBM RCM is an effective process and tool for determining the optimum combination of maintenance types for your facility: Reactive, Preventative, CBM and Proactive When it is decided that condition based maintenance (CBM) is the most appropriate and effective form of maintenance for specific equipment then: Need to determine which PT&I tools will provide the best indication of a fault within the system.