RELIABILITY CENTRED
MAINTENANCE (RCM)
Application within RCAF and
Implementation in OmegaPS
Mike Martin
BRIEFING OUTLINE
Maintenance Environment within RCAF
RCM Process (MSG-3)
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–
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–
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Principles of RCM
Significant Item Selection
Functional FMEA
Level 1 & 2 Decision Logic
Task Assignment and Packaging
Implementation in OmegaPS (FRCM)
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MAINTENANCE ENVIROMENT
WITHIN RCAF
• Maintenance Program part of Design
• Changes tightly regulated
• Conduct of Maintenance on aircraft /
equipment recorded and controlled
• Support to Legacy fleets becoming more
challenging
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WHAT IS RCM?
A Definition:
– RCM is a structured process to identify the appropriate level
of preventive maintenance for an item to:
• Retain inherent levels of performance, reliability and
safety
• Minimize cost of maintenance and failures over the life
cycle
Primary Objectives:
– Ensure safety through PM actions; when PM cannot
effectively ensure safety, redesign is mandatory
– When safety is not a concern, preserve functionality in the
most economical manner with the least impact on
Operations
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WHY DO RCM?
New Programs:
– Requirement of design (ICAs)
– Identify APPLICABLE and EFFECTIVE scheduled
maintenance tasks
– Initial programs conservative and generic
Legacy Programs:
– Able to modify generic programs to suit
environment and fleet performance
– Structured, disciplined approach to substantiating
proposed Design Changes
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FLAVOURS OF RCM
ATA/MSG-3 (***)
RCM II
NAVAIR 00-25-403
NAVSEA S9081-AB-GIB-010
DEF STAN 02-45
Etc
If any question about whether or not a process meets RCM
requirements consult:
SAE JA1011 – Evaluation Criteria for RCM Processes
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STEPS TO PERFORM RCM
Step 1:
Step 2:
Step 3:
Step 4:
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Identify MSI
Perform Functional FMEA
Apply MSG-3 Decision Logic
Level 1 – Failure Effect Code
Level 2 – Task Identification
Package Maintenance Tasks
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MAINTENANCE SIGNIFICANT ITEMS
(MSIs)
– Objective of MSI selection: select appropriate
systems / components for analysis
– Why be selective?
• A/C equipment and systems have many components and
parts
• Analysis of every component on an aircraft would be
unrealistically costly and time consuming
• Failure of many items have no immediate impact on the
a/c as a whole
– RCM derived maintenance program directs tasks
where they matter – at Significant Items
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STEP 1 – IDENTIFY MSIs
– Partition equipment into major functional areas
– Top-down approach; identify items at highest
manageable level
– Item is MSI if failure could:
• adversely effect safety
• Have major operational or economic consequences
• Be undetectable during normal operations
– If in doubt, item should be selected as an MSI
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PARTITION EQUIPMENT
WEAPON SYSTEM
SYSTEM
SUB SYSTEM
LRU
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LRU
LRU
SYSTEM
SUB SYSTEM
SUB SYSTEM
LRU
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MSI SELECTION DECISION LOGIC
ITEM FROM ECIR
MSI 2
MSI 1
NO
IS ITEM STRUCTURE ?
DOES STRUCTURE ITEM HAVE
CURRENT TASK OTHER THAN REMOVE
FOR ACCESS?
YES
MSI 3
NO
DOES ITEM HAVE CURRENT TASK
OTHER THAN REMOVE FOR ACCESS?
NO
YES
RETAIN
TASK
IDENTIFY AS
NON-MSI
YES
MSI 4
NO
COULD FAILURE BE HIDDEN OR NOT LIKELY TO BE
DETECTED BY THE OPERATING CREW DURING
NORMAL DUTIES?
YES
MSI 5
NO
COULD FAILURE AFFECT SAFETY(ON GROUND OR
IN FLIGHT) INCLUDING SAFETY/EMERGENCY
SYSTEMS OR EQUIPMENT?
IDENTIFY AS
MSI
MSG-3
ANALYSIS
YES
MSI 6
NO
COULD FAILURE HAVE A SIGNIFICANT
OPERATIONAL IMPACT?
YES
MSI 7
NO
COULD FAILURE HAVE A SIGNIFICANT ECONOMIC
IMPACT?
YES
IDENTIFY AS NON-MSI
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STEP 2 - FUNCTIONAL FMEA
What are the normal
characteristics of the
MSI?
FOR EACH FUNCTIONAL
FAILURE
INDENTIFY FUNCTION
YES
ARE THERE
ADDITIONAL
FUNCTIONS
?
INCREMENT
IDENTIFICATION FOR
EACH FUNCTION
(eg. 1,2…)
YES
INCREMENT
IDENTIFICATION
FOR EACH
FUNCTIONAL
FAILURE EFFECT
(eg. 1A1, 1A2 …)
NO
FOR EACH FUNCTION
How does the MSI fail
to perform this
function?
ARE
THERE ADDITIONAL
FAILURE EFFECTS
?
NO
FOR EACH FAILURE EFFECT
IDENTIFY FUNCTIONAL FAILURE
CAUSE(S)
IDENTIFY FUNCTIONAL
FAILURE
YES
INCREMENT
IDENTIFICATION
FOR EACH FAILURE
CAUSE
(eg. 1A1A, 1A1B …)
YES
INCREMENT
IDENTIFICATION FOR
EACH FUNCTIONAL
FAILURE
(eg. 1A, 1B …)
What happens when
this functional failure
occurs?
IDENTIFY FUNCTIONAL FAILURE
EFFECT
ARE
THERE ADDITIONAL
FUNCTIONAL
FAILURES
?
NO
ARE
THERE ADDITIONAL
FAILURE CAUSES
?
NO
END FMEA
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RESULTS OF FMEA
For each MSI:
- List of High Level Functions
For each Function:
- List of Functional Failures
For each Functional Failure:
- List of Failure Effects
For each Failure Effect:
- List of Components which cause this
Functional Failure/Failure Effect to Occur
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EXAMPLE OF FMEA
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STEP 3 – APPLY MSG-3 DECISION LOGIC
LEVEL 1 – Identification of Functional
failure Effect (FEC)
LEVEL 2 – Identification of APPLICABLE
and EFFECTIVE Preventive Maintenance
Task
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MSG-3 LEVEL 1 & 2 DECISION LOGIC
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LEVEL 1 DECISION LOGIC
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LEVEL 2 DECISION LOGIC
5A
6A
IS A LUBRICATION OR SERVICING
TASK APPLICABLE & EFFECTIVE?
LUBRICATION/SERVICING
YES
IS A LUBRICATION OR SERVICING
TASK APPLICABLE & EFFECTIVE?
NO
LUBRICATION/SERVICING
5B
IS AN INSPECTION OR FUNCTIONAL
CHECK TO DETECT DEGREDATION OF
FUNCTION APPLICABLE & EFFECTIVE?
YES
INSPECTION/FUNCTIONAL CHECK
NO
YES
NO
5C
6C
IS RESTORATION TASK TO REDUCE
FAILURE RATE APPLICABLE &
EFFECTIVE?
RESTORATION
YES
NO
6B
IS AN INSPECTION OR FUNCTIONAL
CHECK TO DETECT DEGREDATION OF
FUNCTION APPLICABLE & EFFECTIVE?
INSPECTION/FUNCTIONAL CHECK
YES
IS RESTORATION TASK TO REDUCE
FAILURE RATE APPLICABLE &
EFFECTIVE?
NO
RESTORATION
YES
NO
5D
6D
IS DISCARD TASK TO AVOID FAILURES
OR REDUCE THE FAILURE RATE
APPLICABLE & EFFECTIVE?
IS DISCARD TASK TO AVOID FAILURES
OR REDUCE THE FAILURE RATE
APPLICABLE & EFFECTIVE?
DISCARD
YES
DISCARD
NO
YES
NO
5E
IS THERE A TASK OR COMBINATION
OF TASKS APPLICABLE & EFFECTIVE?
TASK/COMBINATION MOST
EFFECTIVE MUST BE DONE
YES
REDESIGN MAY BE
DESIREABLE
NO
REDESIGN IS MANDATORY
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EXAMPLE OF LEVEL 1 / 2
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STEP 4 – TASK PACKAGING
Select Significant Intervals
Fit Others into this interval or multiples
Group Individual Tasks Together By:
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Location
Trade
Complexity
Frequency
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SAMPLE INSPECTION CARD
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TYPICAL INSPECTION
Inspection Tasks (4 trades)
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CURRENT TOOLS
• AEPM Performa
– ADAM data from the field
– Extracted into Excel files
• Maintenance Analyzer (ATESS)
– Access Database
• MSI
• FMEA
• Level 1 / 2 analysis
• Audit
– MS Excel
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CURRENT TOOLS
• Card Deck
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–
–
–
Access Database
MS Word Templates
Contactor Database (IETM)
????
• Scheduling / Planning
– MS Project / MS Excel
– Paper
– ????
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FUNCTIONAL RCM (FRCM)
IN OmegaPS
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FRCM MODULE
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•
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Create FUNCTIONAL structure
MANAGE analysis assignments
Perform FMEA
Audit FMEA
Perform Level 1 / Level 2 analysis
Assign Task and Interval
Audit Level 1 / Level 2 and Task analysis
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CREATE FUNCTIONAL STRUCTURE
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SELECT FUNCTIONAL RCM MODULE
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FUNCTIONAL TREE STRUCTURE
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MANAGER
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DEVELOP FMEA
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OmegaPS FMEA Worksheet
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LEVEL 1 ANALYSIS
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LEVEL 2 ANALYSIS
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LEVEL 1 / LEVEL 2 REPORT
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TASK / INTERVAL IDENTIFICATION
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POTENTIAL OmegaPS MODULE
INTEGRATION
FRCM
PoM
ANALYZER
LORA
PUBLISHER
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Questions?