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Condition-Based Maintenance

LMI. Condition-Based Maintenance. Steve Butcher Logistics Management Institute steve_butcher@msn.com. Conference Theme: Integrating Aging and New Systems Maintenance Track : Condition-Based Maintenance Track Theme: A Snapshot of Service Initiatives.

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Condition-Based Maintenance

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  1. LMI Condition-Based Maintenance Steve Butcher Logistics Management Institute steve_butcher@msn.com

  2. Conference Theme: Integrating Aging and New Systems Maintenance Track: Condition-Based Maintenance Track Theme: A Snapshot of Service Initiatives

  3. Background: LMI Reports to ADUSD on CBM • 1st Report to DoD, August, 2000 Definitions, Technology Assessments • 4 Service CBM Programs • 2D Report to DoD, October, 2000 Management Issues • Have we thought through how to build a CBM system • What are the goals of the programs? • How do we measure success? • Do we have adequate resources (funding) to achieve program goals? • What kind of payback are we getting?

  4. Definition • CBM is a set of maintenance actions based on real-time or near-real time assessment of equipment condition which is obtained from embedded sensors and/or external tests & measurements taken by portable equipment. • Purpose • OPNAV INST 4790.16, Condition-Based Maintenance (CBM) Policy, 6 May 1998 • “The purpose of CBM strategy is to perform maintenance only when there is objective evidence of need, while ensuring safety, equipment reliability and reduction of total ownership cost.”

  5. CBM Starts as an On-System Process • Augmented by portable test equipment at O-level • Supported by a computer network and database managed at I-level or above • Part of an overall Integrated Diagnostics process at all levels

  6. Portable Maint Aid Workstation Workstation Workstation Workstation Network Data Server (At System) (Off System) (On System) Embedded Sensors Current A LAN-connected Maintenance Workstation V Voltage Temperature Pressure RPM Low Speed DAQ Computer Junction Box Ethernet Vibration High Speed DAQ LAN Junction Box Ethernet Vibration CFP Computerized Maintenance Management System Data Bus Trend Data Data- base

  7. Maintenance Strategy Drives CBM(Commercial Example) MACHINE RUN INTERVENTION ACTIONS PLANT MANUFACTURING ASSETS DATA - ONLINE (DCS/PLC, VIBRATION) - OFFLINE( OIL,VIBRATION, PROCESS, ELECTRIC MOTOR) Data Fusion/Plant Archive CORPORATE/ DIVISIONAL/ PLANT RELIABILITY RESIDUAL STRATEGY ECONOMIC CENTERED CONDITION ECONOMIC DECISION MAINTENANCE ASSESSMENT LIFE MGMT STRATEGY ESTIMATION Customer Value Generation Shareholder Value Generation FINANCIAL CMMS MGMT Organizational Learning Internal Plant Process PRODUCTION CONTROL (ERP)

  8. Forces Driving The Need for CBM • Joint Vision 2010 & Focused Logistics • Legacy [Process & Equipment] Problems • Diminishing Resources

  9. Joint Vision 2010 & Focused Logistics • Requires a Re-Invention of Logistics & Maintenance Processes to Achieve the Vision Achieving Anticipatory Maintenance is a Key Capability CBM Enables Anticipatory Maintenance

  10. Legacy Maintenance Process Problems Existing preventive maintenance programs in the Military, many derived decades ago, have these characteristics: • High Cost, Labor intensive • Perform unnecessary maintenance • Don’t prevent catastrophic failure • Have high rates of CND / RTOK / NEOF CBM Can Mitigate These Problems

  11. Legacy Equipment Problem: Our Systems Are Old and Expensive to Maintain • 75% of USAF aircraft are > 20 yrs and will be in the field for at least 10 more years • The average age of USN aircraft is 17 yrs • The submarine fleet service life is 33-42 years • Ground fighting vehicles have been in the field >20 yrs Retrofitting CBM to Legacy Systems is Critical And the Major Challenge Ahead of Us

  12. Today’s Presentations • Ken Jacobs, Director, RCM, NAVSEA • NAVSEA Initiatives in RCM/ CBM • Pat Stevens, Deputy PM, Army PM-TMDE • Army Diagnostic Improvement Program (ADIP) • Andy Hess, Branch Chief, NAVAIR • Joint Strike Fighter Prognostic Health Management System (JSF PHM)

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