Foundations of RCM

This module is an overview of the RCM process.  We’ll set forth the definition of RCM and review key terms.  We’ll lay out the over-arching topics that will be covered in the course.  We’ll finish up by discussing when in asset’s lifecycle RCM should be applied.

Before we start exploring the principles of RCM, it’s essential to know not only how – but why – RCM was conceived in the first place.  That way we can really appreciate the majesty of its principles.  This module takes us back to the commercial airline industry in the mid 1950s.  It’s a gripping story – and one that anyone who is responsible for physical asset management should know and understand.  We’ll cover the events that transformed their philosophy regarding equipment failure.  And we’ll tell the story of how RCM was born and detail the various RCM processes and documents that exist today.  This Module plays an important role in the formulation of your own Asset Management Philosophy.

In this module we’ll review the top three methods used to carry out RCM and we’ll evaluate whether or not each contains two of the main ingredients for a successful RCM analysis.  Through the review of one of the most devastating, yet remarkable, aircraft crashes in U.S. history, we’ll highlight how teamwork is essential to preparation.  We’ll also examine the pros and cons of historical data, in what ways it can be used in an RCM analysis, and how a Facilitated Working Group approach can successfully fill the gaps.  We’ll set forth the benefits of a Facilitated Working Group, describe the logistics of a team approach, and identify what makes Working Groups Effective including characteristics of a capable Facilitator.

In this module we’ll introduce the Operating Context, the document that is prepared prior to carrying out the seven steps of the RCM Analysis.  We’ll talk about why an Operating Context is prepared and we’ll outline the elements that are included in an Operating Context.

In this module, we’ll review the importance of writing Functions and why it’s the first step in the RCM process.  Through the review of three air tanker crashes, we’ll discuss the idea of performance and why it is absolutely critical that the difference between Required Performance and Design Capability is differentiated.  We’ll set forth the two types of Functions – Primary and Secondary – and how to classify them as either Evident or Hidden.  We’ll learn how to compose Functions and how to document them on the RCM Information Worksheet.

Functional Failures is the easiest step in the RCM Process and, relatively speaking, it’s pretty straight-forward.  In this module, we’ll review what a Functional Failure is and identify the two types of Functional Failures – Total and partial.  We’ll also identify how to compose Functional Failures and how to document them on the RCM Information Worksheet.

In this module, we’ll talk about how a properly written Failure Mode puts you on the right road and sends you in the right direction towards formulating technically appropriate Failure Management Strategies.  A Failure Mode is what specifically causes a Functional Failure.  But all Failure Modes have to contain the right amount of detail and be written at the right level in order to formulate meaningful solutions.  We’ll set forth the four questions to ask in order to determine if a Failure Mode should be included in an RCM Analysis.  That way we avoid “analysis paralysis.”  We’ll also show you how to document Failure Modes on the RCM Information Worksheet.

A Failure Effect is written for each Failure Mode.  In this module, we’ll explore what a Failure Effect is, how to write one, what information to include (and how detailed it should be), and how to record it on the RCM Information Worksheet.

The “essence of RCM,” as my mentor, the late John Moubray used to say, is “managing the consequences of failure.”  In this module, we’ll start with an introduction to the RCM Decision Diagram and then learn how to classify Failure Modes as Evident or Hidden.  Then we’ll discover how to assess the Consequences of each Failure Mode as Safety, Environmental, Operational, or Non-Operational.  We’ll finish up the module by talking about how to record Consequences on the RCM Decision Worksheet.

Assigning proactive maintenance and associated intervals is the sixth step in the RCM process.  In this module, we’ll discuss what constitutes “proactive maintenance,” in the context of RCM.  We’ll also set forth the two criteria that must be satisfied in order to assign a proactive maintenance task.  We’ll discuss Scheduled Restoration, Scheduled Replacement, and On-Condition maintenance tasks in-depth.  And we’ll learn how to document these proactive tasks on the RCM Decision Worksheet.

Assigning Default Strategies is the seventh step in the RCM process.  In this module, we’ll discuss Default Checks; Failure Finding Tasks; No Scheduled Maintenance; and other Default Strategies such as engineering redesigns, operating procedure additions, supply changes, technical publication revisions, and training recommendations.  And we’ll learn how to document these proactive tasks on the RCM Decision Worksheet.

Upon completion of an RCM analysis, it must be validated.  In this module, we’ll discuss the Validation and Implementation process.