If your company is just getting started in RCM there is always a level of excitement that goes along with the first analysis.  As a result, when we come to facilitate the first RCM analysis,  we are most often offered the companies problem child of the week or month, and while this could produce some measurable results, I now meet this offer with the request for formal data.

Reliability Centered Maintenance again is all about leadership, structure and discipline, show me the process you used to select your first asset for analysis.  To make RCM become a part of your company culture we need to select winners, critical assets that are suffering with equipment related quality, speed, and operational losses.  Follow this formula, perform your RCM analysis, implement the tasks and we will have a huge winner.

To make this clear, we need to start with critical assets, if your company hasn’t done so you will need to perform a asset criticality assessment.  This can be accomplished a couple of ways, first by hiring a consulting company who has experience in criticality assessment tools, or second by developing a criticality assessment tool and working with operations and maintenance to perform the assessment.  Your asset criticality assessment tool should take in the following criteria as a minimum:

  • Effect on Health/Safety
  •  Effect on the Environment
  •  Effect on Production
  •  Effect on Quality
  • Effect on Energy Usage
  • Effect on the Customer
  •  Cost of Repair

Each asset in your plant should now be ranked as to how it affects each category using a 1 through 5 ranking scale for each category.  Listed below is are the defenitions we developed for the 1 to 5 ranking scale for Effect on Health and Safety:

Probability of Asset Failure

  1. It is highly improbable that a failure could occur 1 in 10,000 years
  2. Failure of this component is not likely. 1 in 1000 years
  3. This asset has failed before on similar assets but not this machine
  4. This asset has failed before
  5. This is a dominant failure mode

Consequence of Asset Failure

  1. Failure of this asset has no impact on the business
  2. Failure results in total expense exceeding $1000
  3. Failure expense exceeds $10,000 or First Aid Injury
  4. Failure expense exceeds $25,000.00 or OSHA Reportable incident
  5. Failure expense exceeds $100,000.00 or Loss Time Incident, Dismemberment or Death

 

   For each asset you will now rank and total probability and consequence and calculate the sum for each consequence category then finish by totaling the sum of all the consequence catagories, this is your asset rank number, those with the highest rank number are your most critical assets

  Now that you have identified your critical assets we should now begin to measure critical asset reliability using OEE (Overall Equipment Effectiveness) and TEEP (Total Effective Equipment Performance) in terms that clearly view good product manufactured and key manufacturing losses.  Good Reliability Engineers use OEE/TEEP as not only a Reliability Measure but as a Reliability Tool to locate where our losses are occurring and what needs to be done to reduce these losses.

Having performed hundreds of RCM Blitz analyses, I can safely say that when fully implemented the RCM Blitz process does a fantastic job of reducing and eliminating equipment related, Operational, Speed and Quality losses.  By eliminating or reducing these losses we can easily provide a return on investment for performing the analysis, implementing the resulting tasks and completing the new and improved maintenance strategy.

The greatest value of performing criticality analysis and tracking reliability measures on your critical assets comes following the implementation of your RCM tasks.  As the reliability of these assets beyond most peoples expectations we can clearly show the value or RCM as reliable assets make all other aspects of the manufacturing business easier.  For those who have never experienced this, reliability makes all of the following easier to perform and more efficient:

  1. Production Scheduling
  1. Staff Scheduling
  1. The Manufacturing of Quality Products
  1. Maintenance Planning and Scheduling
  1. On Time Delivery of Products

       On top of this, companies who understand reliability and have reliable assets have less Health, Safety and Environmental incidents and accidents, the cost of maintenance goes down as well as the cost to manufacture product.  As a result, the unit cost of your products is also reduced and this increases profits, giving your company a competitive advantage in the marketplace!

For more information on GPAllied’s criticality analysis process and tool, visit www.gpallied.com

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