Reliability Centered Maintenance

THE WORKSHOP

Reliability Centred Maintenance (RCM) finds its roots in the early 1960s, when the initial development work was performed by the North American civil aviation industry. “Maintenance Steering Groups” was put together to formulate maintenance strategies that was cost effective, and able to keep their aircraft in a safe operable condition. Over the centuries this technique was formulated and refined into the principle of “Reliability Centred Maintenance” which is today widely used in industries such as petroleum, chemical and pharmaceutical companies, electric utilities, food processing, railways, government agencies, armed forces, facilities and other firms and industries.

RCM is a systematic and structured process used to decide what must be done to ensure that any physical asset, system or process continues to do whatever its users want it to do. It is taking into consideration the primary performance parameters of the asset, possible failure mode and consequence and lastly a suitable failure management policy. 

This workshop is designed to familiarise you with the principles and the process of implementing a RCM program. It will help you to apply the rules of RCM through cross-functional review groups in order to produce robust and cost effective asset management programs, by applying the four maintenance strategies, i.e. corrective, preventive, predictive and pro-active.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

This workshop is intended for all maintenance managers, reliability engineers and technicians directly involved in maintaining and preserving the function of assets. Since the RCM process makes use of cross – functional groups as well as the fact that a lasting maintenance program can only be developed by maintainers and users of the assets, it is also recommended that operation/production personnel attend this workshop to ensure an effective RCM program. These should comprise:

  • Consulting engineers
  • Key leaders from each maintenance craft
  • Maintenance managers/supervisors
  • Operation specialists
  • Planners
  • Plant managers
  • Reliability engineers/technician

CONTENT SUMMARY

RELIABILITY CENTRED MAINTENANCE (RCM) – AN OVERVIEW

  • Evolution of maintenance
  • History of RCM
  • Classical RCM
  • RCM2
  • Streamlined RCM

WHY RCM FOR MY ORGANISATION

  • Why RCM is different
  • The new paradigms in maintaining assets
  • What you should expect from RCM
  • Who should do RCM

PROJECT INITIATION

  • Planning and preparation
  • Setting up review groups
  • Selecting facilitators
  • Selecting the systems for RCM analysis

GATHERING AND BREAKDOWN OF THE BASIC INFORMATION

  • Defining functions and performance standards
  • Defining failure – functional failure
  • Establish root cause of failures – failure modes
  • Identify what happens if failure occurs – failure effect
  • What is the consequence of failure (cost, throughput, quality, safety, environment and customer)
  • FMECA

SELECTING MAINTENANCE TASKS THROUGH PRO–ACTIVE MAINTENANCE (PDM, PM)

  • Scheduled restoration tasks
  • Scheduled discard tasks
  • Scheduled on-condition tasks

TYPES OF PREDICTIVE TECHNIQUES AVAILABLE

  • “The Human”
  • Vibration monitoring and analysis
  • Thermography
  • Oil analysis – rotating and transformers
  • Ultrasonic
  • Magnetic flux
  • Dye penetrant
  • Radiography
  • MPI
  • Eddy current

IF NO PROACTIVE TASK IS AVAILABLE?

  • When and how to do failure-finding (including RCA’s)
  • When to redesign
  • When to run to failure

IMPLEMENTATION

  • Auditing the analysis
  • Developing the maintenance program
  • Continuous improvement
  • KPI’s to measure success

PRACTICAL EXERCISES

  • Breakdown of plant into systems
  • Completing a FMECA
  • Selecting the appropriate tasks for different scenarios
  • Developing the maintenance program – blue print

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