10 rcm 2 slides
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7/28/2019 10 RCM 2 Slides
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پ : )RCM( ی
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پ ی )Reliability-Centered Maintenance(یRCMی ی ی ی ی ک . ی60
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RCM ی ک FMECA ی . گ
RCM ی ک یگ یپ گ ی ی ی یپ یی ک ی ی ی یگ ی . ی
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RCM یچ
ک گ ی ی ی پ ی ی ی کی ی ک ی ی ک ی . ی
RCM"ی کی یپی ی ی گ ی ی _ ی ک
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RCM
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RCM
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RCMOptimizationof PM
Best Maintenance Policy:• Minimize the failures• Minimize the risk of failures
ی ی یی ی پ ی ی
HSE ی ییپ یگ
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RCM ensures that:• the right maintenance isperformed• at the right time• by the right people• in the right way• with the right tools• with the right training
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RCMچ
ی ک 11
Maintenance /InspectionFeedback
Maintenance / InspectionPlan
RiskAssessment
MaintenanceManagementInformationSystem(MMIS)
Remediation & Recommendation
RCM گ
ی -1 ی )System Criticality Analysis( ی
ی ی ...MTTRMTTF ی
ی -2 ی گ
3- گ ی
گ گ پ ی یی ی ....
ی -4 ی
:پ ی ی ی ...HSEی MTTFMTTRی
ی: ی ک ی ی ...ی
ی-5
ی: ک...
ی ک ی ی 12
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CRM گ
ی-6 ی ک ی
ک ک کHSE ک ک ی ک ی ک ی ک ی ... ک
ی -7 ی )RCFA( ک
ی -8 ی )FMECA( ک
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)(RCM گ
ی -9 ی ی گ
ک ک RTFی )Run to Failure( ی
گ ی ی ی ی )PM(یپ
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پ ی ی ک )PaM(ی
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)(RCM گ
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MTTFMTTRی OEE...
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RCM ی
ی ک 17
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RCM
RCM کی ک ی :ی
ی.1
ی .2 ی یی
ی .3 گ ی
ی .4 )Criticality Analysis( ی
یگ .5 یپ
ی.6 ی )Troubleshooting Methodology( ی
ی .7 ی ک )KPI( ک
8.RCFA “What happened analysis?”
9.FMEA “What if analysis?”
10.
ک ی 18
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ی کی ی
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RCM Data Collection & Analysis
Design Data
• System (or Equipment) definition
• System (or Equipment) criticality
• System (or Equipment) breakdown
• System (or Equipment) operation manual
• Technical description (capacity -function…)
• System (or Equipment) performance requirements
• Requirements related to maintenance according to rules
and regulations
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Data Collection
Operational Data
• Operating profile (continuous or batch)
• Process instructions
• Control philosophy “automatic/manual”
• Working conditions
• System (or Equipment) criticality
• Equipment history file
• Maintenance levels and programs
• Trouble shooting and Failure information
• Maintenance and downtime cost elements
• Recommended maintenance for each analysis item
based on manufacture specifications
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ی ک ی پ ی ی ی
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Data Collection
Reliability Data
• Failure modes
• Failure root cause
• Failure mechanism
• Failure effect
• Mean time between failure MTBF
• Mean time to repair MTTR
• Failure rate function z(t)
RCM کی
ی ک 22
Outputs
RCM Outputs
• System (or Equipment) Criticality
• System (or Equipment) Failure Consequence
• Target and Constraints
• Troubleshooting (Failure, cause and remedy)• Root Cause Failure Analysis (RCFA)
• Failure Mode Effect Analysis (FMEA)
• Optimal Maintenance Program (OMP)
• Key Performance Indicators (KPI)
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RCM ی
ی ی
پ ی ی (ک ی Facilitator)ی
)RCM(
ی ی
ی گ ی
ی ی
ی ی ی
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RCM ی
1 ی
ی ی ) یگ (ی
یپ یگ
یپ گ ی
ک ک )KPI( ی
ی ی ی ک
پ )RCM(ی
ی ی )RBI( کی ی ی ی
ی ی )RCFA( ی
ی )FMEA( ک
RCM
2 یی پ ک ی ی ژی گ ی پ
.... ی
ک ی 24
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گ RCM یپ
ی ک 25
RCM Main Steps
1- Study preparation
2-System selection
3- Functional Failure Analysis FFA
4-Critical item selection
5- Information collection and analysis
6-FMECA
7-Maint. tasks
8-M. intervals
Time
9-M. planning
10-M. control
RCMیپ گ
Phase I: Preparation1) Plant overview2) RCM Awareness3) Prime Teamwork (Leader, organization structure)4) RCM Training programs (level I)
Phase 2: System selection (as a pilot system)5) Operational Criticality Assessment (OCA)6) System selection & Overview7) Technical Teamwork (maintenance, inspection,
process, safety)8) Technical Training programs (level II)Phase 3: Maintenance Data Gathering
9) Maintenance Information Collection & Analysis10) Criticality Analysis for the different items11) Targets definition (R, A, CM/PM, MTBF, etc.) , (Short,
medium, long term)12) Constraints definition (incomplete information,
insufficient tools, .. etc)
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گ )(RCM یپ
Phase 4: Failure/Hazard Analysis13) Root Cause Failure Analysis – RCFA (What
Happened? Analysis)14) Failure Mode Effect Analysis – FMEA (What IF?
Analysis)Phase 5: Maintenance Planning
15) Proposed Maintenance Program & recommendations16) Update PM Programs17) Proposed Maintenance Work Orders (weekly, Monthly,
.. etc)Phase 6: Implementation & Feedback
18) Maintenance Work Orders & Feedback19) Feedback Analysis
Phase 7: Performance Evaluation & Sustain20) KPI (Strength & weakness points)21) Corrective Action22) Continuous improvement: Go To Phase 1, 2, 3, 4, or 5
ک ی 27
RCMیپ
کی ی Pilot:12یپ
ی ک 28
Phase Month Schedule
I: Preparation 4
2: System selection 43: Maintenance Data Gathering 4
4: Failure/Hazard Analysis 4
5: Planning 4
6: Implementation & Feedback 4
7: Performance Evaluation 4