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RCM DECISION LOGIC

UNIT II. RCM PROCESS. Module 5. RCM DECISION LOGIC. RCM DECISION LOGIC. Module Preview:. Introduction. Introduction. RCM Decision Logic. Failure Consequences. Task Evaluation. Task Selection. Review and Summary. RCM DECISION LOGIC. Module Objectives:. Introduction.

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RCM DECISION LOGIC

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  1. UNIT II RCM PROCESS Module 5 RCM DECISION LOGIC

  2. RCM DECISION LOGIC Module Preview: Introduction Introduction RCM Decision Logic Failure Consequences Task Evaluation Task Selection Review and Summary

  3. RCM DECISION LOGIC Module Objectives: Introduction • 1. Describe the RCM Decision Logic • Identify the four types of failure consequences that make up the branches of the RCM Decision Logic tree • Describe the RCM Task Evaluation Process

  4. RCM DECISION LOGIC Module Objectives: Introduction • 4. Identify the following task types: • Servicing • Lubrication • On Condition • Hard Time • Failure Finding • 5. Introduce the RCM Task Selection Process end

  5. RCM Process RCM Decision Logic Results PLANNING AND PREPARATION 1. Identify Team and responsibilities 4. Identify and document Review Process 2. Identify analysis items 5. Orientation/Training 3. Prioritize Items 6. Ground Rules and Assumptions Analysis Approach/ RCM Plan ANALYSIS • Equipment Kick-off Meeting • Initial Data Gathering • Hardware Partition • Function • Functional Failure • Failure Mode • Failure Effects • Failure Consequences • Task Evaluation • Task Selection Maintenance Requirements IMPLEMENT RESULTS • Package Maintenance Task • Implement Other Actions Maintenance Program SUSTAIN • Emergent Issues • Age Exploration • Hardware Changes • Trend/degrader analysis • Document Reviews Data

  6. RCM DECISION LOGIC Purpose: RCM Decision Logic RCM DECISION LOGIC Process used to determine what action should be taken to eliminate or lessen the consequences that result from the occurrence of a failure mode

  7. Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? NO Hidden NO Hidden YES Evident YES Evident Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety? Does hidden failure mode in combination with second failure/event cause function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation? Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety? Does failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or lead to serious environmental violation? YES Evident Safety/ Environment YES Evident Safety/ Environment NO Evident Economic/ Operational NO Evident Economic/ Operational NO Hidden Economic/ Operational NO Hidden Economic/ Operational YES Hidden Safety/ Environment YES Hidden Safety/ Environment Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Select BEST OPTION Select BEST OPTION

  8. RCM DECISION LOGIC Consequences of Failure

  9. RCM DECISION LOGIC Use of : FailureConsequences Failure consequences:the impact that the effects of a failure have on safety, operations, and the environment … and whether the failure is evident to the operator • When the failure consequences warrant attention, the goal of RCM is to control the consequences by: • avoiding them (reducing their frequency) • reducing their severity

  10. RCM DECISION LOGIC Identifying: Failure Consequences • Failure consequences are categorized in two steps: • Hidden or Evident • Safety/Environment or Operational/Economic

  11. RCM DECISION LOGIC Identifying: Failure Consequences • Failure Consequences Step 1: • Evident Failure: A failure that, by itself, is apparent to the operator under normal circumstances • Hidden Failure: A failure that is not apparent to the operator under normal circumstances

  12. RCM DECISION LOGIC Question 1: Failure Consequences EVIDENT - Apparent to operator without special monitoring. OPERATOR – Crew/Equipment Operator Is the functional failure or effect of the failure mode, on its own, EVIDENT to the OPERATOR while performing NORMAL DUTIES? Hidden Evident YES NO Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Evident Safety/ Environment Evident Economic/ Operational Hidden Economic/ Operational Hidden Safety/ Environment YES NO NO YES

  13. RCM DECISION LOGIC Identifying: Failure Consequences Failure Consequences Step 2: • The evident and hidden groups are further divided based on failure effects: • Safety • Environment • Operations • Economics #1 #2 2 Fly-ins

  14. RCM DECISION LOGIC Question 2: Failure Consequences Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? Hidden Evident YES NO Does the occurrence of the hidden failure mode/event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Evident Safety/ Environment Evident Economic/ Operational Hidden Economic/ Operational Hidden Safety/ Environment YES NO NO YES

  15. RCM DECISION LOGIC Question 3: Failure Consequences Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? Hidden Evident YES NO Does the occurrence of the hidden failure mode in combination with a second failure/event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Evident Safety/ Environment Evident Economic/ Operational Hidden Economic/ Operational Hidden Safety/ Environment YES NO NO YES

  16. RCM DECISION LOGIC Categories: Failure Consequences • In summary, failures are categorized by consequences. • RCM uses four categories: • Evident Safety/Environmental • Hidden Safety/Environmental • Evident Economical/Operational • Hidden Economical/Operational

  17. RCM DECISION LOGIC Managing: Failure Consequences • Evident failure: • Eliminate/reduce the consequence of single failure • Hidden failure: • Eliminate/reduce consequences of multiple failure • Eliminate/reduce economic consequence of single failure • A Multiple Failure is a combination of a hidden failure plus a second failure or other event that makes the hidden failure evident

  18. RCM DECISION LOGIC Managing: Failure Consequences • Safety/Environmental failure: • Must prevent the consequences of failure • Economic/Operational failure: • Prevent or allow failure • Summary: RCM decision logic process provides the appropriate management strategies for each consequence category

  19. HIDDEN EVIDENT Safety/ Environment Economic/ Operational Economic/ Operational Safety/ Environment Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Select BEST OPTION RCM DECISION LOGIC Consequences Branches: Failure Consequences

  20. RCM DECISION LOGIC Task Evaluation

  21. RCM DECISION LOGIC Purpose: Task Evaluation To determine what actions can be taken to prevent a failure mode from occurring; or, if not prevented, to lessen its effects to an acceptable level.

  22. RCM DECISION LOGIC Preventive Maintenance Tasks: Task Evaluation HIDDEN EVIDENT Safety/ Environment Economic/ Operational Economic/ Operational Safety/ Environment Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Select BEST OPTION

  23. RCM DECISION LOGIC Task Evaluation Servicing: The replenishment of consumable materials that are depleted during normal operations.

  24. RCM DECISION LOGIC Lubrication: Task Evaluation The scheduled lubrication of a component (usually based on the manufacture’s recommendations) where the item’s design requires a non-permanentlubricant for proper operation

  25. RCM DECISION LOGIC Task Evaluation On-Condition Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure.

  26. RCM DECISION LOGIC Hard Time Task: Task Evaluation Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure.

  27. RCM DECISION LOGIC Failure Finding: Task Evaluation A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred.

  28. RCM DECISION LOGIC Preventive Maintenance Tasks: Task Evaluation • S (Servicing Task) - Replenishment of consumable materials depleted during normal operations • L (Lubrication Task) - Replacement of a lubricant based on manufacturer’s predicted or measured life of the lubricant • OC (On Condition Task) - Periodic or continuous inspection designed to detect a potential failure condition prior to functional failure • HT (Hard Time Task) - Scheduled removal of an item or a restorative action at some specified age limit to prevent its functional failure • FF (Failure Finding Task) - A preventive maintenance task performed at a specified interval to determine whether a hidden functional failure has occurred. 5 Fly-ins

  29. RCM DECISION LOGIC Other Action Warranted: Task Evaluation • Other Action: Usually a one time action, other than PM, that will effectively reduce the consequences of failure to an acceptable level • Item redesign • Change in an operational or maintenance procedure • Operating restrictions • Etc.

  30. RCM DECISION LOGIC Other Action Warranted: Task Evaluation • Consider when • No acceptable PM task can be found for safety/environmental consequence failures • Other Action is preferable to PM and run to failure • Other action, in combination with PM, will beneficially reduce consequences or frequency of failure

  31. RCM DECISION LOGIC RCM Decision Logic Results: Task Evaluation • Once a failure mode is subjected to the RCM Decision Logic, at least one of the following outcomes will result: • PM Required • No PM Required • Other Action Warranted

  32. RCM DECISION LOGIC Task Selection

  33. Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties? NO Hidden NO Hidden YES Evident YES Evident Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety? Does the occurrence of the hidden failure mode in combination with a second failure /event cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety? Does the failure mode cause a function loss or secondary damage that could have an adverse effect on operating safety or the environment? YES Evident Safety/ Environment YES Evident Safety/ Environment NO Evident Economic/ Operational NO Evident Economic/ Operational NO Hidden Economic/ Operational NO Hidden Economic/ Operational YES Hidden Safety/ Environment YES Hidden Safety/ Environment Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, No PM, Other Action Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Analyze Options: S, L, OC, HT, FF, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Analyze Options: S, L, OC, HT, FF, No PM, Other Action Select BEST OPTION Select BEST OPTION

  34. RCM DECISION LOGIC Selection Process: Task Selection • One or more PM tasks may prevent or reduce the probability of failure to an acceptable level. These tasks along with... • a decision to allow the failure mode to occur (no PM) • some “other action”... • … form a pool of options from which solutions can be generated.

  35. RCM DECISION LOGIC Review and Summary • Module Objective • Introduction • RCM Decision Logic • Learning Objectives • Task Evaluation • Task Selection 7 Fly-ins

  36. End of Module up next…….. UNIT III RCM Software Review

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