Challenge issued to forum members:

Do you think it is possible to conduct an online RCM Analysis of a system right here on the forum so we can provide a "behind the scenes" look at an RCM Analysis for other forum members?

If so - who is willing to set it up?

Terry O

Great idea Terry,
I have a great example which we use for training. How about I post it and then we can compare approaches - RCM 2, RCM Cost, RCM Turbo, RCM Blitz and PMO2000. I have failure data, drawings and comments from electricians, fitters and operators.
Regards
Steve
www.pmoptimisation.com

That sounds good to me Steve

Let's do it.

Terry O

I'll be around to help if I can.

Which method is best for a large manufacturing environment?

I currently reading a book titled Reliability Centered Maintenance, Implementation Made Simple by Neil B. Bloom. He simplified the Moubray approach and makes it sound easier for a busy manufacturing environment to implement. Manufacturing environments want to implement RCM but cost is always the first concern, followed by support manpower. I'd like to know the best approach for the busy, large scale plant. Neil seems to have the important parts covered in his book.

J-

Terry,

Good idea but need to be careful that it does not develop into a contest between the various consultants to demonstrate that their method is best.

A "free for all" contest would only serve to confuse the forum members rather than to clarify their understanding of RCM.

David

David

I think it may be hard to replicate a "true" RCM analysis because relies on live group participation - the group being the ones with the respective knowledge areas.

Mike.

Mike - good point... However, I have documented the information that the group provides, and if the analysts want to ask questions, I will act as the team. I also have failure history data on some of the information. The failure history is not fully complete so this will make it like reality.
I think this will enable the "theory" of RCM to be delivered.
Now there are many things to facilitation that cant be perfectly replicated on the forum - such as group dynamics and team members that struggle with the concepts etc etc, but I think we can have a good crack at a review.
I need to find a little bit of time to get update the case study - hopefully by the end of the week I can post it and work out how it will run.
Regards
Steve
www.reliabilityassurance.com

Hi David

quote:

Good idea but need to be careful that it does not develop into a contest between the various consultants to demonstrate that their method is best.

A "free for all" contest would only serve to confuse the forum members rather than to clarify their understanding of RCM.

I think two things are important - first the RCM logic and secondly the application. I think it is important that the differences are examined. I am prepared to have our PMO2000 process scrutinised by anyone. Novices should not have too much trouble following the analyses. The point is they can ask questions if they dont understand.
Steve
www.reliabilityassurance.com

Dear All,

I don't think it is possible to develop an RCM in this forum : Why ?

RCM Compose of 3 parts
1) RCM Information worksheet (FMEA)
2) RCM Decision Diagram
3) RCM Decision Worksheet

How can we show this, most specially the decision diagram ?

My Warm Regards,

Steve,

I am sure all the other vendors would also be happy to have their product scrutinised also. I just don't think that this forum is the place to do it. The On-line RCM analysis proposed by Terry is going to be difficult enough without also having to consider and compare the way RCM2 would handle it or RCMCost would handle it or ...RCM Turbo or... RCM Blitz or ... PMO2000... or Navair etc.

Dear All,

With respect to the original question by Terrence O Hanlon. Is it possible to conduct an Online RCM analysis of a system on this forum ?

My understanding is it will come from scratch, lets say a pump failure :

1) then there will be some analysis on its functions, functional failure, failure mode and failure effects.

2) then work on the decision diagram or algorthm and arrive at the decision diagram.

It is not about comparing which is the better method, RCM SAE JA1011 or some streamlined RCM, or having a case study of a finished analysis and comparing the 2 on which is a faster approach.

To start an RCM analysis of a system in this forum will be highly difficult or impossible.

My Warm Regards,

Let's do it. Please provide the template for terry to include in this forum. Forum memebers can see the difference between the different approaches. It was mentioned previously that different consultants give varying results for RBI. I suspect the same for RCM, even for the standard RCM. Or maybe I' wrong....

Yes, this can be done and it would be very simple. Now of course you are not going to have the power of a database or software to sort the information but there is no reason why we couldn't list the function of this pump, the functional failures of the system, the failure modes, effects, consequences and then show how we develop tasks.

So what will be missing? In what context does this pump operate? What are the consequences of failure?

The part that should be interesting is the level at wich we will discuss failures.

We first will need someone to moderate starting by describing the operating context for the pump. This can be followed by folks like Steve and myself replying with a function statement as well as functional failures.

Oh by the way, for those who want to get hung up on comparing methodologies, we could all waste countless hours trying to explain why one method is better than another and the people who are here to learn a little about RCM will be further confused.

I think the objective here is to educate some people on different RCM methodologies and how they would aproach a common asset. When we are done with the discussion, feel free to contact me and I will be willing to send a free copy of a simple pump RCM.

Great Doug,
The case study I have is a fin fan with gearbox and motor etc. It has more variation than a pump. It has things that wear, and things that dont and it has protective devices that are fail safe and ones that aren't.
I will definately have it posted by Monday... I have abuot 35 hours of travel ahead of me on Saturday - Heading to Lima but have to go through NZ and LA. Funny thing is that I arrive in Lima the same day I left.
BTW - good to have you on board Doug - wonder how many other come out of the scrub.
regards
Steve
www.reliabilityassurance.com

Guys,
Here is the introuction to the case study. I have minutes of the workshops and lots of data to come if we can kick this off.
I suggest that some facilitators are appointed. I am happy to facilitate a PMO program. Who is interested in facilitating RCM? We should have a few methods - RCM Cost, RCM Turbo, RCM 2, RCM Blitz. Forum members can work on the analysis on each team.
Any further suggestions or revisions on how to do this? I propose we run in Excel with spreadsheets that can be edited.
Terry OH is looking at a few options. In the mean time, can we have some voluntees to facilitate and any suggestions on how to run it?
Regards
Steve

FinFanCaseStudyforReliabilityWeb.pdf (34 KB, 318 downloads) Fin Fan Case Study Overview

Nice initiative.
Last year I did the RCM2 facilitator training.
I am not very experienced but will be happy to facilitate or participate in an (rcm2)study.

Some live discussion and sharing results is even possible with free tools like netmeeting ?

Great Rogier,
I was begining to think noone was interested. Any others interested? I see the case study has been downloaded 19 times.
Regars
Steve

Ok,
Lets kick off with the functions then. Can someone list the functions

OK Steve - here goes my list (no specific order)

1.To provide constant airflow at a rotational speed of 200RPM
2.To allow access to the fan
3.To indicate speed of the fan
4.To support the motor and gearbox
5.To locate the fan
6.To stop fan in an emergency
7.To contain oil in the gearbox
8.To direct the airflow
9.To lock the fan in position
10.To prevent foreign objects from entering the duct.
11.To support the main fan shaft
12.To transmit power between the motor and gearbox
13.To transmit power between the gearbox and fan
14.To anchor structure in place
15.To shut down the fan when access door is opened.
16.To sound alarm in control room if vibration level exceeds Xm/s.
17.To locate pulleys on shafts.
18.To protect equipment from corrosion.