Reliability-Centred Maintenance
Overview
Reliability-centred maintenance decides what maintenance each asset really needs. This course explains the RCM process step by step: functions, functional failures, failure modes and effects, consequence evaluation and selecting maintenance tasks that are technically sound and worth doing.
Who should attend
Reliability and maintenance engineers, maintenance managers and planners, and operations engineers.
Training methodology
Technical presentations, worked examples and calculations, case studies from industrial facilities, videos, group exercises, and a personal action plan.
Objectives
By the end of this course, participants will be able to:
- Explain the principles and history of RCM
- Define asset functions and functional failures
- Carry out a failure modes and effects analysis
- Evaluate failure consequences and select maintenance tasks
- Plan and sustain an RCM programme
Course outline
Day 1Reliability Principles
- Evolution of maintenance thinking
- Failure patterns
- Reliability and availability
- The P-F interval
- RCM standards
- Discussion: maintenance in your plant
Day 2Functions and Failures
- Operating context
- Defining functions and performance standards
- Functional failures
- Selecting systems for analysis
- The RCM team
- Exercise: define functions
Day 3FMEA
- Identifying failure modes
- Describing failure effects
- Root causes and level of detail
- Criticality ranking
- Using failure data
- Workshop: FMEA on a pump
Day 4Consequences and Tasks
- Hidden, safety, operational and economic consequences
- Condition-based tasks
- Time-based restoration and replacement
- Failure-finding tasks
- Run to failure and redesign
- Exercise: RCM decision diagram
Day 5Implementing RCM
- Turning results into maintenance plans
- Loading tasks into CMMS
- Living RCM and reviews
- Measuring the benefits
- Leading the change
- RCM implementation plan
