Decoding Reliability-Centered Maintenance Process for Manufacturing Industries

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.

• 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