SUSTAINING THE ANALYSIS Module 2 UNIT IV ADDITIONAL TOPICS " Copyright 2002, Information Spectrum, Inc. All Rights Reserved."

Module Preview: Introduction Sustaining Overview Sustaining Overview IntroductionIntroduction SUSTAINING THE ANALYSIS Sustaining Tasks Sustaining Tasks Review and Summary

Module Objective: This module is designed to provide information on sustaining an RCM analysis 1.Identify the purpose and benefit of sustaining an RCM analysis 2.Introduce the two approaches to sustaining RCM 3.Identify the various tasks that may be used to sustain an RCM analysis IntroductionIntroduction SUSTAINING THE ANALYSIS

MaintenanceRequirementsMaintenanceRequirements 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 Analysis Approac h/ RCM Plan Analysis 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 Results IMPLEMENT RESULTS 1.Emergent Issues 2.Age Exploration 3.Hardware Changes 4.Trend/degrader analysis 5.Document Reviews SUSTAIN Sustaining Overview

PurposePurpose The objective of the sustainment process is to continually monitor and optimize the current PM program to: Improve the overall efficiency and effectiveness of the RCM and PM Program Improve the overall efficiency and effectiveness of the RCM and PM ProgramBy: Deleting unnecessary requirements or adjusting intervals Deleting unnecessary requirements or adjusting intervals Identifying adverse failure trends Identifying adverse failure trends Addressing new Failure Modes Addressing new Failure Modes Recognizing the opportunity for insertion of new maintenance procedures, techniques, design changes, and tools Recognizing the opportunity for insertion of new maintenance procedures, techniques, design changes, and tools SUSTAINING THE ANALYSIS

Sustaining Overview Sustaining Approaches:  Continuous (Recommended)  Fastest response to new issues  RCM becomes a way of doing business  Requires a “Champion”  Periodic RCM Reviews  May be preempted by “more important” issues  Data/history may be lost between reviews  May cause the sustainment effort to stagnate  May require re-justification of resources  Should only be used if resources do not permit continuous sustainment continuous sustainment ApproachesApproaches SUSTAINING THE ANALYSIS

Sustaining Tasks Typical Sustaining Tasks:  Emergent Issue Resolution  Age Exploration  Hardware Changes/New equipment  Degrader analysis  Trend Analysis  PM Document/Task Reviews TasksTasks SUSTAINING THE ANALYSIS

Emergent Issues SUSTAINING THE ANALYSIS Sustaining Tasks An RCM Program must establish a process to deal with emergent issues and unpredicted events. Elements may include: An RCM Program must establish a process to deal with emergent issues and unpredicted events. Elements may include:  Problem Assessment  Interim Action  RCM Review and update  Corrective Action The emergent issue resolution process may incorporate or interface with other processes such as Root Cause Analysis The emergent issue resolution process may incorporate or interface with other processes such as Root Cause Analysis Process may vary by organization and should be formally documented Process may vary by organization and should be formally documented

Sustaining Tasks A formal process should be put in place that provides for the collection and analysis of the data generated by RCM recommended Age Exploration tasks. Processes will vary greatly by organization depending on: available data systems, size of organization, etc. Processes will vary greatly by organization depending on: available data systems, size of organization, etc. Age Exploration SUSTAINING THE ANALYSIS

Sustaining Tasks Any change to equipment configuration or added or removed equipment should drive a review of the RCM analysis. Hardware Changes SUSTAINING THE ANALYSIS

Sustaining Tasks Top Degrader ranking identifies items that are having the highest operational or cost impact. Top degrader identification methods:  3M/CMMS (most common)  Operator/maintainer input or records  Any other means that tracks failures, costs, or down-time Top degrader metrics may include:  Maintenance man-hours  Maintenance man-hours per operating hour  Number of Failures  Down-time  Cost Top Degrader Analysis SUSTAINING THE ANALYSIS

Trend Analysis Sustaining Tasks SUSTAINING THE ANALYSIS Trend Analysis provides an indication of systems or components that may be problems in the future or may be deviating from expected performance. Trend Analysis are typically performed using statistical measures such as mean and standard deviations to establish performance baselines and comparing current performance levels to established control levels.  Usually requires automated failure data (3M/CMMS)  Other Statistical Process Control (SPC) processes already in place may be used as a trigger for RCM review

PM Reviews SUSTAINING THE ANALYSIS Sustaining Tasks Periodic reviews of PM requirements (whether stored electronically or on paper) should be accomplished for: Outdated or obsolete maintenance processes, techniques, tools or technology Outdated or obsolete maintenance processes, techniques, tools or technology Opportunities to incorporate new technology or tools Opportunities to incorporate new technology or tools Obsolete, unavailable, or banned consumable materials Obsolete, unavailable, or banned consumable materials Conformance to RCM recommendations Conformance to RCM recommendations

ConclusionConclusion SUSTAINING THE ANALYSIS Sustaining Tasks  RCM requires sustaining to realize maximum benefits  RCM sustaining processes and procedures should be developed and formally documented for each organization implementing an RCM Program

Review and Summary SUSTAINING THE ANALYSIS Learning Objectives Learning Objectives Introduction Introduction Sustaining Purpose/description Sustaining Purpose/description Sustaining Overview Sustaining Overview Provide a basic understanding RCM sustaining Provide a basic understanding RCM sustaining Module Objective Module Objective Sustaining Tasks Sustaining Tasks Emergent Issue Resolution Emergent Issue Resolution Age Exploration Age Exploration Hardware Changes/New equipment Hardware Changes/New equipment Degrader analysis Degrader analysis Trend Analysis Trend Analysis PM Document/Task Reviews PM Document/Task Reviews

End of Module up next…….. Data Considerations End of Module up next…….. Data Considerations