Introduction to Reliability Centered Maintenance

Introduction to Reliability Centered Maintenance Training by Tonex

Introduction to Reliability Centered Maintenance (RCM) training course will provide the knowledge of maintenance strategy required for implementing RCM.

Introduction to RCM training redefines your realization of maintenance management. This hands-on seminar will thoroughly revolutionize the perspectives of maintenance and operations people towards maintenance programs and their responsibilities in that system.

Reliability Centered Maintenance (RCM) is a technique to recognize equipment strategies that encourage maintainability and reliability. RCM introduces the tools to identify sufficient maintenance and operational policies for equipment based on the probability and outcome of its failure modes.

Unlike the traditional approach to equipment maintenance that would concentrate on breakdown and repair, RCM focuses on asset management. RCM training not only modifies perspectives of maintenance but also it improves the relationship between maintenance, operations and engineering towards motivating an effective asset performance.

RCM Training also provides a broader understanding of the organization’s assets in order to introduce an organized way to formally apprehend and handover the knowledge to the other asset stakeholders.

Introduction to RCM training course also teaches you best practices to answer the seven questions of RCM through exercising real world scenarios. Under our coaching, you will investigate the tools necessary for developing a maintenance program in a rational and organized way that determines the hidden, safety, environmental, and operating outcomes of failure.

Added Value of RCM Training

• Maintenance terms
• Importance of maintenance?
• RCM principles and history
• RCM analysis
• Analysis facilitation
• Team approach and deliverables
• Assessment process
• Rigorous and streamlined assessment
• Measuring effectiveness
• Evolution of maintenance
• Origin of RCM
• Maintenance categorization
• The RCM 7 questions
• Functions and standards
• Functional failures
• Causes of functional failure
• Effects of functional failure
• Affect of functional failure
• Preventive functional failure action plan
• Mitigate functional failure action plan

 Audience

Introduction to RCM training is a 2-day course designed for:

• Maintenance personnel
• Plant managers
• Manufacturing engineers
• Rotating equipment engineers
• Maintenance supervisors
• Reliability engineers
• Planners, Schedulers
• Operations Managers
• Supervisors

Training Objectives

Upon the completion of introduction to RCM training, attendees are able to:

• Describe RCM process
• Recognize the differences in RCM techniques
• Identify the importance of data and content prior to conducting any form of strategy operation
• Identifying and categorizing assets
• Understand the importance of FMECA in RCM
• Perform an RCM assessment
• Know how to make the strategy work
• Perform a task comparison
• Identify the work packaging should be done
• Recognize the techniques necessary for RCM implementation
• Understand a living program
• Understand the content of a RCM plan
• Comprehend Risk Based Inspection (RBI) within the asset management support tool

Course Outline

Overview

• RCM definition
• The birth of RCM
• Background of RCM
• Understand the business context of RCM
• RCM standards
• What is criticality matrix?
• Which system to analyze?
• System boundaries identification
• Failure modes, failure causes, and failure effects
• Functions and functional failures
• Consequences
• Predictive and preventive tasks
• Default actions
• The importance of failure characteristics
• Run To Failure (RTF) maintenance
• When do design changes are required?
• How to propose maintenance to critical assets?
• The bathtub curve fallacy
• Cost-benefit considerations

RCM Customization and Requirements

• What is RCM customization?
• How to use RCM template data
• Identifying the required data for RCM
• How to become aware of the Asset Management Support Tool (AMST)

RCM project

• RCM project steps
• Risk Based Inspection (RBI)
• RBI variations
• RBI requirements

The RCM Process Basic Steps

• Preparation
• Analysis
• Task Selection
• Task Comparison
• Task Comparison Review
• Records

 RCM Components

• Reactive maintenance
• Preventive maintenance
• Predictive testing and inspection
• Proactive maintenance
• Acceptance testing

Methodology

• Weibull Distribution
• Problem Description and logic
• Mathematical Terms of Importance
• Mathematical modeling
  • Monte Carlo simulation
  • Reliability growth-Reparability models
  • Exponential, binomial and Poisson models
  • Kaplan-Meier Survivor model
• Risk Background

Practical Applications

• System selection
• System boundaries
• Required materials and documentation
• Plant personnel interviews
• FMECA
  • System functions
  • System functional failure
  • Identification of equipment
  • Identification of failure modes
  • Identification of failure effects
  • Criticality
  • Maintenance criteria for non-critical components
  • Reliability and Performance Data collection and processing
• Use of PSA to support RCM analysis
  • Systems selection
  • Identification of critical components
  • The impact of the maintenance activity changes on Plant Risk
  • The Increased Allowed Outage Time (AOT)
  • PSA capability and insights
• Task selection
  • Task selection guidance
  • Maintenance templates
  • Task selection hierarchy
  • Task options
  • Non critical components
  • Task selection review
  • Final phase of analysis
  • Perform task comparison

Development and Deployment

• Management involvement
• Project management
• Analytical and software tools
• Databases
• Use of contractors
• Conditions monitoring program
• Skills and competences
  • Project management skills
  • Training
• Performance indicators
• Integration into O&M process
• Implementing recommendations
• Living RCM
• Factors for consideration in RCM implementation

Benefits

• Primary goals of RCM – Reliability
• Cost-benefits
• Contribution to long term Operation
• Soft
  • Operations and Maintenance interaction
  • Justification of maintenance tasks
  • Feed back quality improved
  • A culture of economic performance
  • Questioning Attitude

Predictive Testing and Inspection Technologies

• Alerts and alarms
• Vibration monitoring and analysis
• Infrared Thermography
• Ultrasonic noise detection
• Lubricant and wear particle analysis
• Electrical condition monitoring
• Non-destructive testing
• Photography

Predictive Testing and Inspection Criteria

• Baselines
• Criteria by PT&I Technology

RCM Requirements During Facilities Acquisition

• Planning
• Predesign
• Design
• Construction
• Maintenance and operations

RCM Considerations During Facilities Operation

• RCM Program Data
• Maintenance feedback
• Maintenance and operations considerations

 RCM Contract Clauses

• General contract clauses
• Architect and engineering contracts
• Construction contracts
• Equipment procurement contracts
• Maintenance and operations contracts

Checklists for RCM Quality Assurance

• Planning
• Design
• Construction
• Equipment Procurement
• Maintenance and Operations

Key Performance Indicators (KPIs)

• General
• Purposes of KPIs
• Sample KPIs
• Trending Indicators
• Metric selection
• Benchmarking background
• Benchmark section
• Utilization of KPIs
• Planning and scheduling KPIs
• RCM KPIs

 Building Commissioning

• Building Commissioning Overview
• Types of Commissioning
• Commissioning Goals
• Commissioning and Sustainability
• The Commissioning Team
• The Commissioning Process

Maintainability

• Introduction
• Summary
• Maintainability, Reliability, and Availability (RCA)
• Theory of maintainability
• Background
• First principles of maintainability design
• Review for design maintainability considerations
• Replacement and modularity design requirements
• Fault detection and isolation design requirements

Introduction to Reliability Centered Maintenance, RCM Training