UNIT II RCM PROCESS Module 2 PLANNING AND PREPARATION " Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

IntroductionIntroduction Introduction Introduction RCM Planning and Preparations RCM Planning and Preparations Review and Summary Review and Summary PLANNING AND PREPARATION Module Preview:

Module Objective: IntroductionIntroduction This module provides an overview of the elements that must be addressed prior to beginning an RCM analysis and how those issues affect the analysis. PLANNING AND PREPARATION

1. Identify Team and responsibilities 4. Identify and document Review Process 2. Identify analysis items 5. Orientation/Training 3. Prioritize Items 6. Ground Rules and Assumptions PLANNING AND PREPARATION ANALYSIS RCM Process Analysis Approac h/ RCM Plan Analysis MaintenanceRequirementsMaintenanceRequirements MaintenanceProgramMaintenanceProgram DataData 1.Equipment Kick-off Meeting 2.Initial Data Gathering 3.Hardware Partition 4.Function 5.Functional Failure 6.Failure Mode 7.Failure Effects 8.Failure Consequences 9.Task Evaluation 10.Task Selection 1.Package Maintenance Task 2.Implement Other Actions SAE JA Results IMPLEMENT RESULTS 1.Emergent Issues 2.Age Exploration 3.Hardware Changes 4.Trend/degrader analysis 5.Document Reviews SUSTAIN FMECA Planning and Prep

1. Identify the RCM Team and responsibilities 2. Identify the Items subject to Analysis 3. Prioritize Analysis Items 4. Identify and document the analysis review and approval process 5. Project Orientation Brief/Training 6. Develop Analysis Ground Rules & Assumptions Steps:Steps: Planning and Prep PLANNING AND PREPARATION

Step 1: Identify the RCM Team and responsibilities Team composition Team composition Operators Operators Maintainers Maintainers Engineering/Logistics/Safety/SME Engineering/Logistics/Safety/SME Data Managers/Analysts Data Managers/Analysts RCM Analysts (may be one or more of above or separate) RCM Analysts (may be one or more of above or separate) Project Manager/RCM Implementation Manager/Facilitator (one of above or separate) Project Manager/RCM Implementation Manager/Facilitator (one of above or separate) Responsibilities Responsibilities Support roles (subject matter expertise) Support roles (subject matter expertise) Analysis and documentation Analysis and documentation Data collection Data collection Review and approval Review and approval Implementation Implementation Team Availability and Interface Team Availability and Interface Analysis structure (facilitated group or assigned analyst) Analysis structure (facilitated group or assigned analyst) Step1:Step1: Planning and Prep PLANNING AND PREPARATION

Step 2: Identify Analysis Items List the upper level item or items that will be analyzed List the upper level item or items that will be analyzed May be an entire asset or a list of equipment/systems May be an entire asset or a list of equipment/systems Include boundaries if necessary Include boundaries if necessary Be specific Be specific Examples of analysis items: E-6 aircraft E-6 aircraft Sea-wolf Submarine Sea-wolf Submarine Plant water supply System (including well, pumps, and piping up to main shut-off valve) Plant water supply System (including well, pumps, and piping up to main shut-off valve) Water-jet cutting machine and Milling Machine Water-jet cutting machine and Milling Machine Soot Blowing System, Absorber Tower System, and Boiler Air and Gas System Soot Blowing System, Absorber Tower System, and Boiler Air and Gas System Step 2: Planning and Prep PLANNING AND PREPARATION

Step 3: Prioritize Analysis Items (Analysis scope)  List the preferred order that upper level assets will undergo analysis  Does not mean one item must be completed before another starts  In the case of complex items such as an entire aircraft or major system, additional prioritization may be needed after hardware partitioning Step 3: Planning and Prep PLANNING AND PREPARATION

Step 4: Identify and Document the Review and Approval Process Who is responsible for review and approval of each analysis Who is responsible for review and approval of each analysis Are reviews informal or formal, group or individual Are reviews informal or formal, group or individual Review/Approval should include senior RCM analyst and system subject matter expert Review/Approval should include senior RCM analyst and system subject matter expert Step 4: Planning and Prep PLANNING AND PREPARATION

Step 5: Project Orientation Brief/Training Objective is to begin the “buy-in” process and remove potential roadblocks Objective is to begin the “buy-in” process and remove potential roadblocks Should include all personnel significantly affected by RCM results, including operations and management representatives Should include all personnel significantly affected by RCM results, including operations and management representatives Should include the following topics: Should include the following topics: Items in step 1-4 Items in step 1-4 General RCM process overview General RCM process overview What’s in it for everyone What’s in it for everyone What’s expected of everyone What’s expected of everyone Statement of management buy-in Statement of management buy-in Statement of key groups (maintenance, production) buy-in. (team member advocates) Statement of key groups (maintenance, production) buy-in. (team member advocates) Formal analyst training only required for key participants Formal analyst training only required for key participants Step 5: Planning and Prep PLANNING AND PREPARATION

Step 6: Ground Rules & Assumptions (GR&A) A compilation of information required by RCM analysts to perform analysis A compilation of information required by RCM analysts to perform analysis Items included: Items included: - Description of operating environment (operating context) - Standard operating procedures - Data sources - Failure mode sources - Analytical methods - Cost-benefit analysis methods - Default Values - Acceptable probability of failure - Labor rates - Equipment usage rates Step 6: Planning and Prep PLANNING AND PREPARATION

RCM Program Plan Planning and Prep RCM Projects should document the results of the planning and preparation steps into an RCM Program Plan Scope and size of plan is dependent on project Scope and size of plan is dependent on project Ensures consistency of analysis process Ensures consistency of analysis process Establishes priorities and schedule Establishes priorities and schedule Documents contributions of team members and concurrence by management Documents contributions of team members and concurrence by management Can be used for funding justification and to gain management support Can be used for funding justification and to gain management support PLANNING AND PREPARATION

RCM Program Plan Planning and Prep RCM Program Plan Elements: Team and Responsibilities (Planning Step 1) Team and Responsibilities (Planning Step 1) Analysis scope (what and what order: Planning steps 2 and 3) Analysis scope (what and what order: Planning steps 2 and 3) Review and approval process (Planning Step 4) Review and approval process (Planning Step 4) Training Requirements (Planning Step 5 +) Training Requirements (Planning Step 5 +) Ground Rules and Assumptions (Planning Step 6) Ground Rules and Assumptions (Planning Step 6) Sustaining task procedures Sustaining task procedures Hazard Risk Matrix Hazard Risk Matrix Metrics and Reporting requirements Metrics and Reporting requirements Funding requirements Funding requirements Plan of action and milestones Plan of action and milestones Contractor support requirements Contractor support requirements Deliverables Deliverables PLANNING AND PREPARATION

Team and Responsibilities Planning and Prep Facilitated approach vs. dedicated analyst Facilitated group approach Facilitated group approach Analysis is performed during meetings of key personnel in presence of a facilitator Analysis is performed during meetings of key personnel in presence of a facilitator Maximizes buy-in from participants Maximizes buy-in from participants Limited by amount of time key persons can attend meetings Limited by amount of time key persons can attend meetings Focuses on consensus of stakeholders vice detailed/analytical solutions Focuses on consensus of stakeholders vice detailed/analytical solutions PLANNING AND PREPARATION

Team and Responsibilities Planning and Prep Facilitated approach vs. dedicated analyst Dedicated analyst Dedicated analyst Analysis is performed by dedicated RCM expert(s) using information gathered from system experts and other sources Analysis is performed by dedicated RCM expert(s) using information gathered from system experts and other sources Still must include participation of key SMEs (operators/maintainers) for analysis to be effective Still must include participation of key SMEs (operators/maintainers) for analysis to be effective Less daily impact on non-RCM analyst participants Less daily impact on non-RCM analyst participants Participants don’t need extensive RCM training, just basic orientation Participants don’t need extensive RCM training, just basic orientation More conducive to outside analytical assistance (outsourcing) More conducive to outside analytical assistance (outsourcing) PLANNING AND PREPARATION

Team and Responsibilities Planning and Prep Facilitated approach vs. dedicated analyst Which is best? Depends on desires and resources of each organization PLANNING AND PREPARATION

Scope of Analysis: Planning and Prep Scope May be dependent on: Funding/personnel resources/management commitment Funding/personnel resources/management commitment Pilot project vs. full-scale Pilot project vs. full-scale Objectives of analysis Objectives of analysis Fix current “headaches” vs. maintenance optimization Fix current “headaches” vs. maintenance optimization “Age/Remaining planned Life” of analysis items “Age/Remaining planned Life” of analysis items Potential risk vs. return Potential risk vs. return Criticality analysis (Risk Indices) may be used to further prioritize or limit the analysis Criticality analysis (Risk Indices) may be used to further prioritize or limit the analysis MUST ensure potential safety/environmental issues are not overlooked in less than complete analysis! PLANNING AND PREPARATION

RCM Training Planning and Prep Training Requirements (Planning Step 5 +) Orientation Orientation Provided to significantly affected parties and participants early in the process Provided to significantly affected parties and participants early in the process Essential in the dedicated analyst approach Essential in the dedicated analyst approach Typically 2 – 4 hours Typically 2 – 4 hours Analyst training Analyst training Analyst approach: only required for those key individuals intimately involved in the analysis process Analyst approach: only required for those key individuals intimately involved in the analysis process Facilitated approach: typically provided to all participants Facilitated approach: typically provided to all participants Typically 3-5 days Typically 3-5 days Management overview Management overview Provided to key management to gain buy-in develop agreement on expectations Provided to key management to gain buy-in develop agreement on expectations Typically 1-4 hours Typically 1-4 hours PLANNING AND PREPARATION

Sustaining the RCM Analysis: Defines how the RCM team plans to monitor and improve the effectiveness of the maintenance program throughout the life of the equipment Defines how the RCM team plans to monitor and improve the effectiveness of the maintenance program throughout the life of the equipment RCM must be maintained over time to realize its full benefit RCM must be maintained over time to realize its full benefit RCM Sustainment is discussed in more detail in Unit IV PLANNING AND PREPARATION Planning and Prep

Review and Summary Introduction Introduction – Learning Objectives Planning and preparation Planning and preparation – Required Steps – RCM Plan – Provide an overview of the issues that must be accomplished prior to that must be accomplished prior to beginning RCM analysis. beginning RCM analysis. Module Objective Module Objective PLANNING AND PREPARATION

End of Module up next…….. Hardware Partitioning End of Module up next…….. Hardware Partitioning