Decoding Reliability-Centered Maintenance Process for Manufacturing Industries: 10th Discipline on World Class Maintenance Management - Hardcover

Angeles, Rolly

Hardcover

ISBN 10: 1649456077 ISBN 13: 9781649456076

Publisher: Rolando Santiago Angeles, 2021

Synopsis

Although RCM is a popular maintenance strategy that originated from the United Airlines, many manufacturing industries are still not implementing this process and continue to remain stuck in their current PM tasks. The main reason for writing this book is that doing RCM in a manufacturing plant is a bit different from doing RCM in an oil and gas, power plants, and other similar plants because their equipment losses are different. There are many cases when breakdowns and failures are not the primary cause of equipment downtime.  Although the process of how RCM is done will be the same. If you worked in a semiconductor plant, breakdowns and failures are not the main problems on the machines, but minor stoppages, changeover, and quality problems are.  What is important is to know thy boundaries between what RCM can address and what it cannot. 
 
RCM will address failures and breakdowns by proposing a maintenance tasks.  However, RCM  is not designed to address every possible equipment loss since failures and breakdowns are just a subset of the entire equipment loss. Suppose you have chronic quality problems caused by the equipment, RCM can address some of them, but not all, since Quality problems and defects are much broader than breakdowns and failures. I have a detailed explanation of what particular losses RCM can and cannot address in Chapter 3.3.2 of this book. This book is written to help provide detailed guidelines in implementing RCM for manufacturing industries on their machines, equipment, and assets.
 
Some of the highlights of this book include:
- 27 Frequently Asked Questions (FAQ) on RCM
- 22 Tips on Implementing RCM- 15 Don'ts About RCM
- Why the RCM Preparatory Stage is Important
- Detailed Guidelines in Doing the RCM Preparatory Step
- Can RCM Address All Equipment Losses?
- Actual Case Study on RCM: Air Handling Unit Case
- Role of Operators in the RCM Analysis
- How to Integrate RCM into the TPM Process
- Bonus: RCM Forms in Excel Format
- The RCM and TPM Crossroads - Do they have different or the same paths?
- Strengthening the SAE JA1011 Criteria
- Addressing MRO Spare Parts after Implementing RCM
- How to Determine the Correct Interval for PM, PdM, FFT, and Switching Standby Components
- MRO Decision Diagram on Whether to Stock or Not to Stock
- Difference Between a Failure Mode and a Root Cause
- Secondary Tasks for Doing On-Condition Tasks
- Detailed Guidelines in Writing the RCM Decision Worksheet Explained
- Detailed Guidelines in Writing the RCM Information Worksheet Explained
- Detailed Guidelines in performing Horizontal Replication for Similar Equipment with a similar Operating Context
- Detailed Guidelines in Conducting the RCM Audit and more . . .
 
RCM can be explained in two folds, on the equipment side, and on the human side.  From an equipment perspective, Reliability-Centered Maintenance is a process used to determine any physical asset's maintenance tasks, decisions, and requirements in its current or present operating context.  It is also a process used to determine what must be done to ensure that any physical assets continue to do whatever their users want them to do in their present operating context. From the human perspective, RCM is a way or process of capturing and extracting the knowledge, experience, and wisdom of the most experienced people in the plant and transforming it into a living document and their legacy.
 
RCM can transform our maintenance task to be more Proactive than Reactive.  This means that RCM will allow us to be 1 or 2 steps ahead of the failure instead of the equipment failing, then reacting to it.

About this title

About the Author

• Mr. Rolly is one of the World Class Best Trainers I have come across during my 30 plus years career. The course was built up very methodically in the simplest way. His presentation skills and his command of the various Maintenance Strategies made the Workshop very interesting. Mr. Rolly is one of the few Maintenance Professionals I have come across, attached, and dedicated to the Maintenance Profession. His wealth of experience and his humor made the RCM Workshop even more interesting. The structuring and delivery of the concept enable all the participants to initiate RCM studies very confidently. The training material provided by Mr. Rolly was excellent and was prepared with great care to ensure that all the participants have fully been benefited. I am sure that all the participants in this three-day Workshop have been benefited from his technical and intellectual sharing of his knowledge. From Srinagesh Dy, General Manager, Reliance Industries Ltd., India.

• Rolly Angeles is one of the best trainers (World Class) I have ever met in my life. The delivery of the RCM course by him was so smooth and straight to the point.Besides, he combined technicality with intellectualism, thereby carrying even the most assumed idle time along.The definition of the different tasks in RCM caught most of my attention. The RCM Information Worksheet simplifies the course to enable an ideal team to develop the best maintenance strategies. Although it is a challenge to convince the management team that is not trained on RCM to adopt, I will still insist that RCM is the best maintenance strategy worldwide. From Kalu-Kalu, Head of District Maintenance, Nigeria

From the Back Cover

RSA Reliability and Maintenance Book Series

• World Class Maintenance Management-The 12 Disciplines: Many industries are looking for ways to achieve a World Class Maintenance Management Level. This book details the 12 Disciplines of Maintenance to achieve a level of World Class Maintenance. The book is easy to absorb as it is structured into three parts: the Basics, the Strategies, and the Advance Disciplines. This book aims to address the very basics first before doing the strategies and the more advanced disciplines.

• Maintenance-Roadmap to Reliability: This is a sequel to my first book on World Class Maintenance Management, the 12 Disciplines. This book provides a detailed systematic roadmap for achieving a high level of Reliability for industries' equipment and assets. There is no better way to start the journey to Reliability than to go back to the basics and address the very small problems we have in our plant.

• Reliability-A Shared Responsibility for Operators and Maintenance: This book is a sequel to my first and second book and discusses the importance of having an operator and maintenance partner for industries. The message of this book is simple and straightforward industries cannot escape the vicious cycle of being reactive unless they realize the importance of operators in the reliability strategy. It is time for the separation between operators and maintenance to end and, finally, a partnership. Improving Reliability is not the sole responsibility of the maintenance function.

• Cutting-Edge Maintenance Management Strategies: This book also deals with the different cutting-edge maintenance strategies that industries must adopt to survive their competition. In industries today, the law of the jungle applies, survives, or is left behind. Learn how these strategies can link together in building a solid maintenance structure in the plant.

• Problems and Solutions on MRO Spare Parts and Storerooms: This book covers the most common problems in MRO Spare parts and storerooms and how to deal with each of these problems. One highlight of this book is that it provides the readers with an algorithm or MRO decision diagram to determine what parts to stock or not to stock in their storeroom.

• Lubrication Tactics for Industries Made Simple: An easy-to-read book that provides the different strategies applied to lubricating grease and oil for equipment and assets to lessen lubricants' cost failures attributed to lubrication failures.

• Decoding Reliability-Centered Maintenance for Manufacturing Industries: This is a detailed and easy-to-read book designed for manufacturing industries to successfully implement RCM in their equipment and assets. These industries suffer from failures and breakdown losses as well.

From the Inside Flap

• Chapter 1: An Introduction to RCM covers the introduction of both RCM and maintenance itself. Its evolution, the traditional or common belief of most maintenance in industries, and so on. Although it is quite interesting that the discovery of RCM can be traced back to the works of Tom Matteson, Bill Mentzer, Stanley Nowlan, and HowardHeap," the discovery of infant mortality was first observed by C.H.Waddington, who is not even maintenance himself.

• Chapter 2: RCM Preparatory Stage refers to the preliminary activities that must be done to make the RCM process more holistic and complete. I have detailed all the requirements needed before even proceeding with the RCM analysis. One of the highlights I mentioned in this book addresses the equipment's basic equipment condition through restoration. The basic equipment condition includes addressing leaks of all kinds, correct lubrication, complete bolts on the machine with the correct torque, and having clean equipment.

• Chapter 3: Deriving the RCM Information Worksheet explains the first part of the RCM process, which derives a simple FMEA of the equipment by identifying the functions, functional failures, and the failure mode of the asset in its present operating context. It also provides the requirements on how to write the details from the function to the failure effects. One of the most important discussions in this chapter is identifying the different losses that equipment can suffer and explaining if RCM can address this particular equipment loss. A detailed guideline on how to write the RCM Information Worksheet is also provided at the end of this chapter. This chapter also will accomplish the first four questions on RCM.

• Chapter 4: Understanding the Different Failure Consequences explains the risks, criticality, and consequences of failures. It also examines the different consequences that can happen if a particular failure mode exists. Failure consequences can either be a hidden failure, safety, environmental, operational, or non-operational consequences. This chapter answers the fifth question on the RCM process regarding in what ways failure matter.

• Chapter 5: Feasibility of Using Preventive Maintenance Tasks justifies when to use preventive Maintenance tasks. A survey on the Top 10 problems on Preventive Maintenance, which I started in 2009 and included in my previous books, is finally concluded in this chapter. This chapter also clarifies what Preventive Maintenance is and some misconceptions about it, and what industries are doing wrong in their PM tasks. I also reveal how to correctly determine the interval or frequency of doing preventive maintenance.

• Chapter 6: Feasibility of Using On-Condition Tasks clarifies the feasibility of when to use these tasks. Both Chapters 5 and 6 answers the sixth question on the classical RCM, predicting or preventing failure. We point out the importance of the P-Interval and why it is important to any user. I also discussed the most common Predictive Maintenance tools such as Vibration Monitoring, Infrared Thermography, Conducting Oil Analysis, determining the interval for monitoring, and doing a replacement or overhauling interval P-F curve reaches 80 to 90%. A guided step-by-step detail is provided for those industries that want to implement a CBM or PdM strategy in their plant.

• Chapter 7: RCM Default Tasks covers the final question on RCM. If there are no suitable Preventive or Predictive tasks that can address the failure mode, then the use of the default tasks will be considered. The default tasks will include Failure Finding Tasks, switching intervals for redundant components, run to fail, and lastly, modification or redesign. We have also explained that Failure Finding Tasks will only be applicable if the failure mode is hidden. Run-to-fail tasks will not be feasible if the failure mode has safety or environmental consequences.

• Chapter 8: The Decision Diagram, the Heart and Soul of RCM, decodes and explains how to use the algorithm or decision diagram. An example is provided in detail for the readers to follow using the RCM decision diagram. I have also provided a detailed itinerary on how long it will take to complete an RCM analysis, although we also need to consider the asset complexity and the time the RCM team will be allotted to conduct their meetings.

• Chapter 9: RCM Decision Worksheet discloses how the proposed tasks and the initial interval are derived from RCM decision diagrams. A detailed step-by-step guide is provided on how to accomplish the RCM decision worksheet. Although the initial tasks and intervals are now written to address a particular failure mode. Our aim is to decide what to do before the failure actually happens in the asset. We can predict, prevent, manage, control, prolong, or allow the failure to occur. We also emphasize that Precision Maintenance can be used to write the maintenance tasks so that whoever will perform the tasks will have the same outcome. Lastly, there will also be tasks that will default to the operators, so operators should be part of the RCM team.

• Chapter 10: Guidelines in Implementing RCM reveal a step-by-step guideline for implementing the RCM analysis from the start until its completion. We also provide detailed criteria for auditing the RCM team and their Analysis. This chapter also provides an audit or certification guideline to check the RCM analysis's completeness before actually implementing it on the equipment. Lastly, a detailed guideline is also provided to replicate the RCM tasks to similar equipment with the same operating context and sustain the RCM process once implemented in the asset or equipment.

• Chapter 11: RCM Case Study: Air Handling Unit (AHU) is an actual case study on RCM, starting with how the operating context was derived, writing the RCM information worksheet, and finally, the RCM decision worksheet. We also showed the process of how to arrive at the final maintenance tasks. There is also a big possibility that the interval can change, especially if the basic equipment condition had been established. Finally, the replication process is shown if these activities will also be done on similar equipment and assets.

• Chapter 12: FAQs, Tips, and Don'ts on RCM talk about the most frequently asked questions on RCM that have been asked during my class, as well as the answers to them. This chapter also covers some key points and tips about RCM. Lastly, this chapter discusses the don't's and the most common reason RCM fails industries.

• Chapter 13: Integrating RCM into the TPM Methodology reveals the TPM (Total Productive Maintenance) concept and integrates the RCM structure for a more robust and powerful structure. This chapter also explains the similarities and differences between the two powerhouse methodologies and how to integrate RCM into the TPM pillar of Planned Maintenance. Although these methodologies come from different origins, TPM from the east and RCM from the west, these two methodologies can complement each other.

• Chapter 14: Addressing MRO Spare Parts after RCM Implementation points out the importance of adjusting and reviewing their MRO spare parts for those parts affected by the RCM analysis, especially the intervals.

• Chapter 15: RCM Roadmap and Forms provides the readers an idea regarding the actual forms that my team and I generated in implementing RCM in our plant.

• Chapter 16: The Conclusion discloses and justifies that manufacturing industries should start doing RCM analysis in their equipment and assets to minimize their losses and maintenance costs. These industries need to believe in transitioning from reactive to proactive in their maintenance tasks, as this is whatever the industry wants. Lastly, I shared my mantra on maintenance.

Edition details

• Publisher: Rolando Santiago Angeles
• Publication date: 2021
• Language: English
• ISBN 10: 1649456077
• ISBN 13: 9781649456076
• Binding: Hardcover
• Number of pages: 426