Reliability Centered Maintenance Streamlined with LEAN

Reliability Centered Maintenance (RCM) is a process used to determine what must be done to ensure that a physical asset (Machine – production stage – etc.) continues to do what its users want it to do in its present operating context for the longest possible period at the highest possible efficiency. It poses the following questions:

• What do its users want it to do?

• In what ways can it fail?

• What causes it to fail?

• What happens when it fails?

• Does it matter if it fails?

• Can anything be done to predict or prevent the failure?

• What if we cannot predict or prevent the failure?

RCM has a long and rich history of success in improving asset performancefor industries and companies around the world and in many different industries. Withso many different ways to follow how can acompany interested in adopting RCM determine what approach to take? RCM II is the more rigorous development of RCM.

In this course participants will learn from about RCM’s history and its founding principles. We will gradually build a maintenance system based on RCM principles. Interactive sessions simulating an RCM analysis will provide participants with some appreciation of the RCM process and its relation to other maintenance methodologies.

This version of the session is customized to include the concepts of LEAN management and how it can be applied to reduce all different kinds of process wastes so that our Maintenance Management Systems is not only effective (RCM) but also flowing with minimum waste and maximum efficiency (LEAN)

Case studies will be presented throughout the course to relate to practical side.

This session redefines your understanding of maintenance management and will completely transform the way that maintenance and operations people view the development of maintenance programs and their roles and responsibilities in that process.

Who should attend?

• General Managers
• Plant Managers
• Operations, Engineering and Maintenance Managers
• Senior / Junior Operations and maintenance Engineers
• Senior technicians with potentials for higher responsibilities in Maintenance Management

Module 1: Background    

• Introduction              
• Historical Evolution of RCM
• RCM II vs RCM (RCM III?)
• Reliability Centered Maintenance Goals              
• Types of Maintenance
• Standardization and SOPs

Module 2: Measuring your progress: Key Performance Indicators (KPIs)

• Selecting Key Performance Indicators
• Rules to follow in applying metrics
• Examples
• Maintain and Publish the Track
• RCM Metrics

Module 3: Understanding Failures

• Failure    
• System and System Boundary        
• Function and Functional Failure             
• Failure Modes      
• Failure Characteristics      
• Preventing Failure      

Module 4: RCM foundation: Root Cause Analysis, RCA

• Chronic vs. Sporadic Problems
• What RCFA is and why it is done?
• 7 Generic Steps in an RCFA
• Failure Analysis Methods
• FMEA Procedure – the core of the maintenance management system
• The Ishikawa Diagram
• Fault Tree Analysis
• Pareto Charts

Module 5: The RCM Process streamlined with LEAN Management

• Process definitions and basic analysis
• SIPOC and VSM
• What are process wastes
• Defining Wastes using DOWNTIME tool
• Basic process improvement using ECRSA
• LEAN visual environment – Applying 5S methodology
• Using Poka-Yoka to stop mistakes
• Muda Mura Muri
• Building RCM process
• RCM Decision Diagrams
• Implementing RCM recommendations       

Module 6: Other RCM Program Components       

• Statistics in Maintenance
• Precision Rebuild and Installation       
• Failed-Part Analysis      
• Rebuild Certification/Verification       
• Recurrence Control       
• Introduction to SAE JA1011 and JA1012

Module 7: Putting it into action: Maintenance Planning & Scheduling

• Measuring workload
• Planning Principles
• Scheduling Principles
• Periodic Maintenance Scheduling (Daily – weekly – other)