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RCM Ala Maximo

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RCM Ala Maximo
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    Reliability Centered Maintenance (RCM) and MAXIMO An MRO Software White Paper January 2004 Version 3.0 Timothy H. Trout, C.P.M.M. Johan Arts MRO Software 100 Crosby Drive Bedford, MA 01730 Tel: +1 (800) 244-3346 Fax: +1 (781) 280-2202 www.mro.com   Reliability Centered Maintenance and MAXIMO 1.    Introduction...........................................................................................................3   2.   What is Reliability Centered Maintenance? ........................................................3   3.   Why invest in RCM?.............................................................................................6    4.    Assessing readiness for RCM...............................................................................7    5.    Implementing RCM using MAXIMO...................................................................8   6.   Customer case .......................................................................................................9   7.   Conclusions...........................................................................................................9   8.    About MRO Software..........................................................................................10   9.    Sources:...............................................................................................................10   MRO Software ©2003 Page 2 1/27/04  Reliability Centered Maintenance and MAXIMO 1. Introduction The purpose of this paper is to explain what Reliability Centered Maintenance (RCM) is and how MAXIMO, the Strategic Asset Management Solution from MRO Software can be used to implement an RCM based maintenance program. The paper also includes a customer case that describes the results achieved by a MAXIMO customer that has implemented an RCM based maintenance program. 2. What is Reliability Centered Maintenance? Reliability Centered Maintenance (RCM) is the concept of developing a maintenance scheme based on the reliability of the various components of the system or product in question. Implementing a preventive maintenance program using RCM can greatly reduce the total cost of ownership of any product or system. RCM evolved during the 1950s in the aircraft industry as a result of a number of major reliability studies concerning complex equipment. There have been a number of significant studies concluded that challenged the traditional approach to scheduled maintenance programs which were based on the concept that every item on a piece of complex equipment has a ‘right age’ at which overhaul is necessary to ensure safety and operating reliability. Through these ‘reliability programs’ it was discovered that many types of failures could not be prevented or effectively reduced by such ‘right age’ overhauls. Two items from the findings of the 1960 FAA / Airline Industry Reliability Program study were: ã scheduled overhauls had little effect on the overall reliability of a complex item unless the item had a dominant failure mode; and ã there were many items found for which there was no effective form of scheduled maintenance. Therefore, the traditional views of equipment failure as depicted by the First Generation (pre World War II), and the Second Generation (post World War II) curves were challenged and a new series of Third Generation failure curves were developed relating to specific types of equipment. MRO Software ©2003 Page 3 1/27/04  Reliability Centered Maintenance and MAXIMO The First Generation pattern indicates a ‘fix it when it breaks’ maintenance strategy. The Second Generation pattern indicates a more engaged maintenance strategy, realizing as equipment became more complex the need for maintenance to be involved at installation and startup was as necessary as their being involved upon failure. While the Third Generation patterns indicate that various equipment components reflect different failure trends. Those patterns are: Pattern Example Equipment Type A Mechanical Equipment B Wear Resistant Liners, Gear Boxes C Piping, Refractory, Valves D Hydraulics or Pneumatics E Lubricated Ball Bearings F Electronic Circuit Boards Because of the Third Generation failure patterns, it became obvious that views of equipment failure needed to change, as did what should be done to prevent failure. Imposed age limits and Time-Based Maintenance schedules often do little or nothing to improve the reliability of complex equipment. As shown in the drawing, traditional maintenance can actually increase failure rates by introducing infant mortality into otherwise stable systems. Because of this there were four challenges that were recognized as requiring maintenance to provide resolution: MRO Software ©2003 Page 4 1/27/04
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