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Course objectives

By the end of this course participants will:

• Realize that maintenance is done based on the consequences of a failure and not the failure itself
• Know when to use which maintenance task by using a Decision Diagram
• Understand the importance of identifying and categorizing assets
• Understand criticality and the FMECA approach in RCM
• Conduct an RCM analysis and know the implications of making the strategy work
• Understand what scheduling packaging is
• Understand what is required for successful RCM implementation
• Understand that maintenance is a living program

Who should attend this workshop?

• Asset and Maintenance Managers
• Maintenance and Production Engineers
• Operations Managers
• Senior Engineering Planners
• Anyone who wants to optimise their capital investment through the improvement of the performance of their physical assets.

Benefits of the course

By the end of this programme the delegates will have a full understanding of RCM and how to apply it for the review of existing and the development of new maintenance schedules. Through the use of practical case studies delegates will learn the practicalities of applying RCM effectively. In addition, they will learn the concept of the RCM Task Force and how to launch an RCM Programme in their own organisations.

Workshop outline

DAY 1

Module 1: Introduction to RCM

Outcomes:
This learner will:
• Have a definition of Reliability-Centered Maintenance
• Be able to describe the history of RCM
• Know the benefits of RCM
Contents:
1. What is RCM and are its objectives
2. The history of RCM
3. Benefits of RCM

Module 2: Failure Patterns

Outcomes:
The learner will:
• Understand the concepts of failure patterns
• Be able to interpret each failure pattern
• Draw conclusions from the various failure patterns
Content:
1. Basic philosophy of traditional maintenance
2. 6 Failure curves and what are these curves telling us?
3. The relationship of time to failure

Module 3: RCM Terminology

Outcomes:
The learner will know basic concepts and terminology used in the RCM process.
Content:
1. Failure Terminology: Functional Failure, Potential Failure, Failure Mode
2. The concepts of Severity, Probability of Failure, and Criticality how they are related
3. Maintenance terms:Scheduled Maintenance, Unscheduled Maintenance, Preventive Maintenance, Corrective Maintenance, Proactive Maintenance, Reactive Maintenance, Condition Monitoring, Condition Based Maintenance, Conditional Maintenance

Module 4: Overview of the RCM Process

Outcomes:
The learners will know the overall RCM process including the basic elements of an RCM effort.
Content:
1. Planning and preparation
2. Initial RCM analysis
3. Implementation of results
4. Monitoring and optimizing results

Module 5: Preparation for RCM

Outcomes:
The learners will:
• Know the functioning of the RCM teams
• Be able to develop a Hardware Partition
• Show how performing RCM at different levels affects the analysis
Content:
1. RCM teams and responsibilities
2. Hardware partitioning
3. Documenting review and approval process
4. Ground rules and assumptions
5. Exercise: Hardware partitioning

Module 6: Failure Mode Effect and Criticality Analysis

Outcomes:
The learners will:
• Know the meaning of the FMECA terms: Function, Functional Failure, Failure Mode, Failure Effect, Failure Detection, Severity Classification, Mean Time between Failures
• Be able to perform a FMECA
Content:
1. What is a FMECA?
2. The purpose of FMECA
3. The RMECA process
4. Exercise: Criticality Analysis
5. Exercise: FMECA

DAY 2

Module 7: RCM Decision Logic and Model

Outcomes:
The learners will:
• Know the RCM Decision Logic and Model
• Be able to identify the four types of failure consequences that make up the branches of the RCM Decision Logic tree
• Know the RCM Task Evaluation Process
• Exercise: RCM analysis
Content:
1. RCM Decision Logic
2. Task evaluation
3. Task selection
4. Exercise: Basic RCM Analysis

Module 8: Packaging Maintenance Schedules

Outcomes:
The learners will:
• Understand maintenance task packaging
• Be able to demonstrate the different options for packaging maintenance tasks
• Be able to identify issues that can impact packaging decisions
Content:
1. Definition and concept: Combining discrete tasks
2. Package types: Calendar, Operating units, Convenience, Phase
3. Task groupings: Grouping considerations

Module 9: Implementing RCM

Outcomes:
The learner will:
• Understand the different term approaches
• Participate in RCM Review groups
• Know the basics of RCM facilitation
Content:
1. Implementation strategies - Short term vs. long term
2. RCM review groups
3. Role of the RCM facilitator

Module 10: Monitoring RCM programmes

Outcome:
The learner will know how to develop processes and procedures for sustaining RCM
Content:
1. Sustaining overview: Sustaining purpose/description
2. Sustaining Tasks: Emergent Issue Resolution, Age Exploration, Hardware Changes/New
Equipment, Degrader analysis, Trend Analysis, PM Document/Task Reviews

About your facilitator

Eric Maclear is Managing Director of Resource Techniques SA (Pty) Ltd. In Johannesburg, South Africa. He is a highly respected management consultant with more than 25 years experience. For the past 15 years he has been running his own consulting and training company. He is a trained and qualified Industrial Engineer having studied both locally and internationally. He holds a B. Eng degree and has completed a number of Business School Programmes.

Eric has had much experience in Asset & Maintenance Management and has a
particular interest in Reliability-centred Maintenance and Root Causes Failure
Analysis. He has held a number of senior management positions with high profile
international companies. He began his consulting career in 1980 with an Australian based management consultancy where he completed a number of assignments in implementing planned maintenance systems. He later worked for a prominent SA consulting firm consulting and training in the full spectrum of plant operations. During his career as a management consultant he has successfully completed many assignments across a broad spectrum of industries, facilitated many training courses, and was keynote speaker at international conventions. He has also written and published numerous papers on Root Cause Failure Analysis. Eric has facilitated training courses in Southern Africa, USA, UK, China and Middle East.