module 3 terminology & concept
TRANSCRIPT
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Module 3
UNIT I
"Copyright 2002, Information Spectrum, Inc. All Rights Reserved."
INTRODUCTION TO RCM
RCM TERMINOLOGY AND
CONCEPTS
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IntroductionModule Preview:
Failures
Introduction
Severity
Probability of Failure
Reliability
Types of Maintenance
Review and Summary
Criticality
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Module Objective:
This module will introduce basic
concepts and terminology used in theRCM process.
Introduction
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Module Objective: Introduction
1. Define Failure Terminology:
Functional Failure
Potential FailureFailure Mode
2. Introduce the concepts ofSeverity,
Probability of Failure, and Criticalityand
how they are related.
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Module Objective: Introduction
3. Introduce the concept ofReliability.
4. Define the following maintenance terms:- Scheduled Maintenance - Unscheduled Maintenance
- Preventive Maintenance - Corrective Maintenance
- Proactive Maintenance - Reactive Maintenance
- Condition Monitoring - Condition Based Maintenance
- Conditional Maintenance
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FAILURES
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FailureDefinitions:
1. FAILURE:An identifiable deviation from aspecified condition that is unsatisfactory to an
asset owner or manager.
RCM recognizes two types of failures:
FUNCTIONAL FAILURE -Inability of item toperform a specific function within specifiedperformance limits
POTENTIAL FAILUREDefinableanddetectable condition that indicates a
functional failure will occur
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FailureDefinitions:
2. FAILURE MODE - A specific physical
condition that causes a particularfunctional failure
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SEVERITY
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SeverityDefinition:
SEVERITY - A category assigned to a
failure mode based on the impacts of itspotential effects
qualitative measures used to
categorize the potential effects of failures.
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CATEGORY I (CATASTROPHIC)
Death or Permanent disability
Destruction of system/equipment
Significant breach of environmental
regulation Damage > $1M
CATEGORY III (MARGINAL)
Damage >$10K and < $100K
Degraded ability to perform critical mission
Interrupted operations
CATEGORY II (CRITICAL)
Personal Injury
Inability to perform primary mission
Damage >$100K and < $1M
CATEGORY IV (MINOR)
Unscheduled maintenance or repair
Damage
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CATEGORY I (CATASTROPHIC)
Death or Severe Injury
Significant Environmental Impact
Loss of availability > 1 week
Damage > $1M
CATEGORY III (MARGINAL)
Loss of availability > 4 hrs and < 24 hrs
Damage >$10K and < $100K
CATEGORY II (CRITICAL)
Minor Injury
Loss of availability > 24 hrs and < 7 days
Damage >$100K and < $1M
CATEGORY IV (MINOR)
Loss of availability < 4 hrs
Damage
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PROBABILITY OFFAILURE
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Probability of FailureDefinition:
1.Probability of failure: The probabil i ty that a given failuremode wil l occur dur ing a defined period.
2.Acceptable Probability of Failure (Pacc):Theprobabil ity of a given failure mode occurr ing during a defined per iod that
is acceptable to a program or asset manager.
The more severe the consequences, the lower Pacc
should be
Values may be defined by regulatory organizations
or self imposed (by a program or asset manager)
Values should be documented prior to analysis
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Probability of FailureDefinition:
3. Actual Probability of Failure (Pact): The predictedor demonstrated probabil i ty of a given failure mode occurr ing dur ing
a defined per iod in the operating environment.
Pactcan be measured from in-service data or estimated
from statistical failure distributions
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CRITICALITY
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CRITICALITY - A prioritization of the
combination of failure severity and failure
frequency (or probability)
Sometimes referred to as Risk
Criticality may bedocumented qualitatively
or quantitatively(Ref: MIL-STD-1629)
Asset managers/Programs may define
acceptable criticality limits by use of aHazard Risk Matrix. (Qualitative Method)
Criticality can be used to set priorities for
analysis or define acceptable risk
CriticalityDefinition:
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Hazard Risk Matrix:FREQUENCY
SEVERITY
FREQUENT(A)
> 1 per 1,000Hours
PROBABLE (B)
> 1 per 10,000Hours
OCCASIONAL (C)
> 1 per 100,000Hours
REMOTE (D)
> 1 per 1,000,000Hours
IMPROBABLE (E)
< 1 per 1,000,000Hours
CATASTROPHIC (I)
CRITICAL (II)
MARGINAL (III)
MINOR (IV)
Death or Permanent disability
Significant Environmental breach
Damage > $1M, Downtime>2 days
Destruction of system/equipment
Personal Injury
Damage >$100K and < $1M
Loss of availability > 24 hrs and
< 7 days
Damage >$10K and < $100K Loss of availability > 4 hrs and
< 24 hrs
Damage
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RELIABILITY
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Reliability
RELIABILITY - Probability that an
asset will perform its intended
function for a specified period of timeunder specified operating conditions
Actual Reliability is a function of the assets design,
manufacturing process, usage profile, operating
environment, and maintenance program.
Definitions:
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MAINTENANCETERMS
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Types of MaintenanceDefinition:
PREVENTIVE MAINTENANCEactions
performed periodically (or continuously)
prior to functional failure (or multiple
failure/demand requirements for hiddenfailures) to achieve the desired level of
safety and reliability for an item
These actions are performed to prevent orreduce consequences of failures.
Due to differences in the way the termScheduledMaintenanceis used, this course will attempt to use thetermPreventive Maintenanceonly
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Types of MaintenanceDefinition
PROACTIVE MAINTENANCEany tasks
used to predict or prevent equipmentfailures.
Similar toPreventive Maintenanceexcept that itgenerally excludes failure finding type tasks. Again,
definitions may vary
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Types of MaintenanceDefinition:
CORRECTIVE MAINTENANCErepairs
or other corrective action taken after afailure has occurred
For the purposes of this course, the termUnscheduled
Maintenanceis synonymous withCorrective MaintenanceandReactive Maintenance
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Types of MaintenanceDefinition:
CONDITION MONITORINGThe use of
specialized equipment to measure the
condition of equipment.
Vibration Analysis, Oil Analysis, and Thermography
are examples ofCondition Monitoringtechniques
Predictive Maintenance (PdM) and Prognosis and Health
Management (PHM) are usually interchangeable with
Condition Monitoring.
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Types of MaintenanceDefinition:
Condition Based MaintenanceAn
equipment maintenance strategy based
on measuring the condition of
equipment in order to assess whether
it will fail during some future period,
and then taking appropriate action toavoid the consequences of that failure.
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Types of MaintenanceDefinition:
Conditional or Opportunity Maintenance
Maintenance actions conducted as result of a
specific condition, or as a result of specific
circumstances or events.
Examples of Conditional Inspections
Hard Landing
Unscheduled disassembly
Power Interruption Over/Under Voltage
Lightning strike
Over stress
Unscheduled or scheduled shut-down
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Proactive Maintenance
Preventi ve Maintenance (PM)
Unscheduled Maintenance
Corrective Maintenance (CM)
Reactive Maintenance
Condition Based Maintenance
Condition Monitori ng
Predictive Maintenance
Prognosis Health Management (PHM)Potential fail ures
Repair s or corrective actions
Run to failu re
Failure has occurred
Preserves required functionality
Reduces unplanned downtime
Requires investment
Fixes failures in unplanned manner
Downtime unpredictable
Addresses only whats broken
RCM determines proper balance of planned and unplanned maintenance,along with Other Actions, to establish a Failure Management Strategy
Scheduled Maintenance
Types of MaintenanceSummary:
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Review and Summary
Introduction
RCM Terms & Concepts
Learning Objectives
Failures Severity
Probability of Failure
Criticality
Reliability
Maintenance Terms
Module Objective
Introduce the primary terminologyand basic concepts used in RCM
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End of Moduleup next..Unit II Module 1 RCM Process Overview