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com
Website: www.lifetime-reliability.com

Implementing Reliability Centered Maintenance RCM

From Analysis to Action (online course by distance education)
Module 1
Item Key Topics Design/Topics Benefits
1 Foundation Physics of Failure  Identifies the types
Reliability  Why parts fail of situations that
cause equipment
Knowledge Equipment Failure Curves failure
 Early Life – Random – Age  Explains why
 Maintenance strategy selection maintenance is done
 Explains equipment
Risk Management life-cycle strategies
 The components of risk
 Measuring risk
Maximum Reliability
 Series and Parallel Systems
 Life-cycle considerations
 Quality and Precision
 Human Factors
2 Recognising Equipment Criticality  Match maintenance
Equipment  Identifying systems critical to plant safety and profitability and matching and reliability
management
Risk the maintenance effort. strategies to
Activity 1 – Perform Equipment Criticality Analysis operating risk

3 Identifying Failure Modes and Effect Analysis (FMEA)  Methods to

Effects of  Identifying failures and ways to eliminate them eliminate possible
failure increases the
Failure  Identifying the root-cause reliability and
 Feasible ways (technically) of analysis integrity of
equipment
Activity 2 – Perform an FMEA
Activity 3 – Access Failure Consequences
Activity 4 – Identify Hidden Failures
4 Proactive Maintenance Strategy Selection  Highlight possible
Maintenance  Selecting Preventive and Predictive Tasks to maintain reliable plant issues/challenges of
maintenance
equipment in the most cost-effective manner while meeting the challenge  Getting the bigger
of regulatory compliance. picture of the
 Operating Risk Reduction with RCM to identify the most practical, cost- issues, possible
solutions and
effective and technically correct tasks in maintaining equipment function benefits of
 Precision Maintenance and how workmanship quality produces high implementation
reliability  Which selections
will actually deliver
Case Study1: Maintenance Strategy for Gas Compressor/Turbine from reliability
RCM Analysis improvements
Activity 5: Maintenance Strategy Selection from FMEA Activity
5 Making Changing to Better Maintenance Practices  To get the
Reliability  Purpose of RCM – on-condition based maintenance increased reliability
and integrity of
Centered  RCM – The 7 basic questions equipment that
Maintenance  Describing and listing functions RCM can deliver
Work  Performance Standards needs the proper
practices to be
 Applying the RCM process introduced and used
 What RCM achieves: Example RCM Maintenance Strategy Development
 Measuring likely improvement of RCM strategy
Case Study2: Fuel Terminal Automated Valve RCM
Activity 6 – Confirm Value of a Chosen Maintenance Strategy
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 Email: info@lifetime-reliability.com
Website: www.lifetime-reliability.com

Module 2
Item Key Topics Design/Topics Benefits
6 Integration of Design Principles of Low-Cost, Usable, Reliable,  The principles of reliable
RCM and Maintainable & Safe System and maintainable, high
performance plant
Implementation  Identifying Project and Operating Risk  Ways of integrating all the
of Strategies  Setting Reliability Standards knowledge obtained in Day
 Reducing Operating Risk at Design 1 and implementing it for
 Maximizing Availability the benefit of the
organization
 Controlling Human Factors
 Effective implementation
 Quality Control – setting pass/fail criteria uses key metrics to better
 Importance of Standardization utilize resources, enhance
 Accuracy controlled procedures coordination among related
projects and improve
Activity 7 – Develop an ACE 3T error proof procedure project planning and
Case Study 3: RCM of a Flow Control Valve estimation;
 Proactively identify the
Activity 8 – Do an RCM on a Pump Set risks of failing to complete
the schedule and budget
Case Study 4: Change Management – How a Power Provide targets; reduce the process
moved from Third Quartile to Top Decile Ranking overhead of measurement
Metrics to track effectiveness of equipment data collection,
consolidation and analysis
 Metrics to check the effectiveness of RCM implementation at different levels in the
 Proactive Condition Monitoring project hierarchy
 MTBF improvement measures  How to make RCM really
 Duane/Crow-AMSAA plots work
 Operational improvement measures
7 Optimize Your  Creating a Useful Maintenance Management System  Easily share RCM
Maintenance Access, standardize all relevant information regardless of location knowledge —benchmark
standards best practices,
Systems and format (work orders, maintenance schedules, regulatory maintenance history,
requirements, resource skills) regulatory guidelines, etc.
 Maintenance Planning and Scheduling among those who need it, in
Optimize RCM plans and schedules (taking into account a form that works best for
them
priorities, skill sets, time and Resource constraints, etc); track  Establish a mature
work orders and resource usage maintenance process early
 Developing and Implementing RCM with a Limited Staff in the plant life to maximize
 Standardize equipment and parts the effectiveness of the
RCM program, minimize
 Precision Operation – degradation management unnecessary activities, and
 TPM - Operator Maintenance activities increase the reliability and
 Precision Maintenance skill set worth of plant & equipment
 Teamwork Organisation Structure  RCM for sites with a small
number of maintenance and
 Error-proofing work activities
operations staff
8 Looking Techniques of Reliability Growth  Apart from the short RCM
Forward -  Weibull Analysis – recognizing failure causes method covered in the
course, there are new
Modernization  Human Factors Management Maintenance Optimization
in Reliability  Reliability Growth Cause Analysis (RGCA) ideas that can be used
Activity 9 – Conduct an RGCA
9 Take Home Case Study 5 – Implementing RCM in the Australian Coal  Provide Attendees with
Plan Industry initial actions to improve
their plant performance by
Activity 10 – Attendees identify list of activities to increase or using RCM
optimize reliability at their facility and develop first-steps
implementation plan

DO A WORKPLACE RCM ACTIVITY

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