Reliability Centered Maintenance Process Research Articles

A Case Study Maintenance Task Allocation Analysis on Marine Loading Arm Using Reliability Centered Maintenance

Marine Loading Arm (MLA) supports all liquid bulk loading and unloading activities, especially imports of chemical raw materials such as NH3, H2SO4, and H3PO4. Therefore, to minimize the occurrence of failure it is necessary to have a treatment method. Reliability Centered Maintenance (RCM) is a maintenance method that focuses on increasing the reliability of components in the system. The RCM uses the principle of risk management to determine tasks and maintenance schedules appropriately. The RCM process is implemented using American Bureau Shipping (ABS) Guidelines. According to the results of this research, there are three types of maintenance tasks for MLA, in which category A has 14 maintenance tasks, category B has 21 maintenance tasks, and there are no maintenance tasks in category C. In all maintenance categories for Preventive Maintenance by 54% with 19 tasks, for Condition Monitoring of 37% with 13 tasks, while for Run-To-Failure of 9% with 3 tasks.

Adopting machine learning and condition monitoring P-F curves in determining and prioritizing high-value assets for life extension

Many machine learning algorithms and models have been proposed in the literature for predicting the remaining useful life (RUL) of systems and components that are subject to condition monitoring (CM). However, in cases where data is ubiquitous, identifying the most suitable equipment for life-extension based on CM data and RUL predictions is a rather challenging task. This paper proposes a technique for determining and prioritizing high-value assets for life-extension treatments when they reach the end of their useful life. The technique exploits the use of key concepts in machine learning (such as data mining and k-means clustering) in combination with an important tool from reliability-centered maintenance (RCM) called the potential-failure (P-F) curve. The RCM process identifies essential equipment within a plant which are worth monitoring, and then derives the P-F curves for equipment using CM and operational data. Afterwards, a new index called the potential failure interval factor (PFIF) is calculated for each equipment or unit, serving as a health indicator. Subsequently, the units are grouped in two ways: (i) a regression model in combination with suitably defined PFIF window boundaries, (ii) a k-means clustering algorithm based on equipment with similar data features. The most suitable equipment for life-extension are identified in groups in order to aid in planning, decision-making and deployment of maintenance resources. Finally, the technique is empirically tested on NASA’s Commercial Modular Aero-Propulsion System Simulation datasets and the results are discussed in detail.

Reliability-centered maintenance and cost optimization for offshore oil and gas components

Reliability-Centered Maintenance (RCM) is widely used for enterprise asset management in the Oil and Gas sector. The traditional RCM process encompasses the development of equipment hierarchy, the determination of the functional failure of assets, identification of the critical failure modes and the development of suitable maintenance strategies for these failure modes through RCM logic tree analysis. However, the current industry standards and conditions call for greater strides of production availability and reliability of the assets. The aim of the paper is to deliver RCM oriented cost optimization framework for the assets through the implementation of probabilistic and statistical analysis. Probabilistic analysis of the most critical components predicts the failure over time. The mean time to failure, mean time between failure and mean time to repair parameters are determined from the failure history. The parameters of the probability distribution, for instance, the shape and scale parameters of Weibull distribution determine the failure pattern of the failure mode over time. The cost optimization modules allow the analyst to determine the optimum intervals for maintenance or replacement of the maintainable items. The integrated RCM methodology, therefore, provides quantitative and cost-effective solutions for asset maintenance and management. A case study of an equipment in the Oil and Gas sector will be presented to illustrate the optimization framework.

Implementation of Reliability Centered Maintenance Method for the Main Engine of Tugboat X to Select the Maintenance Task and Schedule

Tugboat is the supporting system that plays an essential role in port. A tugboat used for maneuvering, primarily pulling or pushing bigger vessel in open seas or river to be able to lean in port. PT.X known as a company has a prominent business field in provides such as tugboat. On the PT. X Annual Report of 2018 reported several cases that caused that related to the reliability of the main engine. The failure occurred on the main engine, affected commission days targeted was not achieved. Reliability-Centered Maintenance (RCM) is a maintenance method that focused on elevating the reliability of a component in the system(s). RCM used a risk management principle to determine the maintenance task and schedule appropriately. RCM process implemented using the Guide for Survey Based on Reliability-Centered Maintenance (RCM) by the American Burau of Shipping (ABS). Based on the results of this research, there were 38 task list type which is obtained based on the analysis of maintenance task allocation and planning. The percentage of maintenance types from each failure mode (task type) Preventive Maintenance (PM) is 29%, Condition Monitoring (CM) is 29%, Finding Failure (FF) is 21% and One-Time Change (OTC) is 21%. Work package for each interval is created from every failure mode for each interval for maintenance/inspection.

Data-driven decision-making for equipment maintenance

Industrial parks, science parks, university campuses, tourist complexes are springing up greatly in developing countries. Decision-making on equipment maintenance of these areas where facilities intensively locate differs from that of industrial systems or plants in two features: 1) it needs regular repetition and update because equipment replacements, facility renovations and equipment condition changes often happen during the operation phase, 2) the accumulated maintenance data in these areas are large enough to be used for decision-making. However, existing approaches to decision-making on equipment maintenance have not considered such features. To fill this gap, this research aims to propose a data-driven approach for decision-making on equipment maintenance by integrating three technologies: Reliability Centered Maintenance (RCM), Building Information Modeling (BIM) and Geographic Information System (GIS). By implementing quantitative decision-making models and Monte-Carlo simulation, a data-driven RCM process is proposed. BIM and GIS are integrated to support the acquisition and update of data required for the proposed RCM process. Based on requirement analysis and architecture design, a prototype system is developed and verified by using a virtual campus. The results show that the proposed approach reduces labor cost and diminishes difficulties of decision-making on equipment maintenance. This paper contributes to the body of knowledge in that it provides an objective approach for the decision-making on equipment maintenance. For future improvements, the approach is compatible with the Internet of Things (IoT) technology to support more efficient data acquisition as a basis for decision-making on maintenance.

Reliability-based preventive maintenance strategies of road junction systems

PurposeThe purpose of this paper is to present a study of reliability-centred maintenance (RCM), which is conducted on the key sub-assets of a newly constructed road junction infrastructure in Nigeria.Design/methodology/approachThe classical RCM methodology, a type of RCM, which has a top down, zero-based approach for maintenance analysis, is implemented in this study.FindingsThe implementation of the classical RCM is successful in its application of various PM policies assigned to the assets and it shows that its application in the highway industry could reduce excessive maintenance backlog and frequent reactive maintenance by effective optimisation of its preventive maintenance (PM) intervals.Practical implicationsRoad junctions are originators of more than 70 per cent of road traffic congestion and account for high accident rate. The traditional methods of reliability assurance used in the highway industry such as reactive maintenance and routine maintenance are often inadequate to meet the round the clock usage demands of these assets, thus the consideration for the application of a systematic RCM process for maintaining the system function by selecting and applying effective PM tasks.Originality/valueIt uses an approach that critically develops and analyses thoroughly preventive and continuous maintenance strategy in a new circumstance with environment of uncertainty and limited operating data. The case-based reasoning cycle has been applied in the RCM approach with real-time data obtained from a UK-based network maintenance management system for highway infrastructures.

A Conceptual Framework to determine Medical Equipment Maintenance in Hospital Using RCM Method

Maintenance services are performed to ensure the equipment is operating according to manufacturer standard and maintained at a desired level of quality. The implementation of maintenance services may prevent unexpected breakdown and disruption of operations in a hospital. However, there were numbers of cases reported on the frequent breakdown of medical equipment even though the maintenance program is in place and practised. Therefore, the reliability of the maintenance services was questioned especially when the breakdowns occurred after the maintenance services being performed. This paper proposes a conceptual framework to determine the accurate maintenance program for medical equipment in the hospital using Reliability Centred Maintenance (RCM) method. The recommendation from the RCM will assist to identify the root cause of the breakdown and minimize the number of breakdown for medical equipment in the hospital. RCM process is known as one of the most effective maintenance approaches to reduce the number of maintenance activities and hence minimizing the cost of maintenance incurred.

Maintenance Task Allocation And Planning In KT. X Tugboat Using Reliability Centered Maintenance Method

Reliability Centered Maintenance (RCM) as one of the processes that used to decisive action which should be performed to ensure any physical components or a system can work optimally in accordance with the function desired by its users. Basically, RCM used a risk management principles of the failure of the components so that it can be determined the type of maintenance properly. With the appropriate type of maintenance, then the failures that may occur can be prevented at once to be able to be detected before they occur. Appropriate implementation of RCM, capable of delivering cost savings, the impact on both the cost of maintenance as well as repair costs due to the occurrence of failure. In this paper, the components become the object of research is the main engine of the KT. X tugboat belongs to Pelindo Marine Service (PMS) Surabaya. KT. X tugboat has the lowest level of availability of the entire company-owned tugboat 80.01 percent. Tugboat is one of the main assets of PMS who support the economy of the company. Therefore, it is imperative for a company to further enhance the efficiency of activities of its operations. These include the efficiency of human resources, as well as economic analysis of system reliability of company assets. It is used in order to keep abreast of competition at the world maritime national and globally. Implementation of RCM process on main engine KT. X, priority levels can be specified against the failure of components that have critical consequences. So it can be a planned maintenance system generated properly and efficiently.

What Is RCM and How Could It Be Applied to the Critical Loads?

Reliability-Centered Maintenance (RCM) is a proven technology to optimize the maintenance processes and another logical step in improving the overall performance and reliability of the critical facility while reducing the total cost of ownership. This paper will introduce RCM and use an automatic transfer switch and a standby generator to back up utility power as the example system to demonstrate the RCM process.

철도차량의 유지관리 최적화를 위한 RCM 프로세스 개발 및 적용

Abstract - Recently, RCM(reliability centered maintenance) proc ess is introduced and applied for the planning and implementing efficient and effective maintenance s ystem in terms of optimal rolling stock maintenance. Particularly, cost-time benefits analysis associat ed with the implementation of RCM for rolling stock maintenance is necessary and required for railway operato r in advance. The RCM process was primarily starting from military, airplane and nuclear industri es and is now adapted in railway industry for local railway operators. This paper focuses on suggesting t he way of connecting the RCM process with railway maintenance activities in the railway operation fi eld. Thus, in order to introduce and establish reliability activitie s, it needs to review and evaluate the main-tenance environment in the organizational point of view. Based on these reviews and evaluations, various maintenance methodologies are reviewed for customizing local ra ilway field situations and establish specific process in the application of major systems on the reliability technology. In this paper, the railway RCM process is proposed for the establishment and construction of t he systematic and optimal maintenance system.

Reasoning in reliability-centred maintenance based on a Dempster—Shafer approach

This approach to modelling of uncertainties in reliability-centred maintenance (RCM) is a continuation of the probabilistic and the fuzzy RCM. The evidence measures, belief and plausibility, are applied to express the uncertainties of experts in reasoning and to give weighted recommendations during the RCM process. Brief introductions to RCM and to the Dempster—Shafer theory are given. Finally, the Dempster—Shafer approach to RCM (DS-RCM) is applied to a fire detection and extinguishing system.

Computer-aided RCM-based plant maintenance management system

In most of the industries, classical reliability-centered maintenance (RCM) is employed to decide the maintenance strategies using reliability data without having adequate interaction with the design and operational systems. This means that the RCM process will be conducted with no or limited access to the design and operational data/knowledge. Commonly, the developed maintenance strategies are implemented and managed within the computerized maintenance management system (CMMS), which is usually separate from the RCM automated environment. This paper presents the detailed system design and mechanism of improved RCM process as integrated with CMMS. The proposed solution is integrated with design and operational systems and consolidates some successful maintainability approaches to formulate an effective solution for optimized plant maintenance. The major components of the enhanced RCM process are identified and a prototype system is implemented as integrated with the various modules of the adopted CMMS (MAXIMO™). A case study is used to show the effectiveness of the proposed RCM-based CMMS solution in optimizing plant maintenance over the traditional approaches.

Maintenance strategy for tilting table of rolling mill based on reliability considerations

Abstract Reliability centred maintenance (RCM) is a new strategic framework for ensuring that any asset continues to perform, as its users want it to perform. RCM is a process used to determine the maintenance requirement of any physical asset in its operating context. RCM process entails asking seven questions about each of the selected assets. It makes use of two documents namely, RCM information worksheet and RCM decision worksheet. RCM decision diagram integrates all the decision processes into a single strategic framework. RCM concept developed by US commercial airlines industry has been successfully implemented by Military, Navy, Nuclear power plants, electric power generation and distribution undertakings and several other sectors. These projects have been carried out in the United Kingdom, The Republic of Ireland, the United States, Hong Kong, Australia, Spain and Singapore. The fact that people has enthusiastically received RCM at all levels and has enabled users to achieve some remarkable successes in all of these countries, suggests that it can be universally employed. Literature review indicates that RCM approach is not conventionally applied in process industries in India. Presently, predictive maintenance (PDM) approach along with conventional preventive maintenance is used in continuous/process industries. This approach if implemented in totality will increase the production cost to a large degree and make the production uneconomical. Similarly breakdown maintenance (BDM) approach cannot be applied in such industries as each breakdown involves huge costs. RCM approach is a compromise between PDM and BDM approach for optimising the cost and ensuring the availability of machine. The RCM approach has been applied to the tilting table system of rolling mill for the research work reported in this paper. In the present study, preventive maintenance tasks suggested for power transmission subsystem, guiding and transportation subsystem and hydraulic subsystem in tilting tables are 14 scheduled on-condition tasks, 10 scheduled on-restoration tasks, seven scheduled discard task. Whereas for 14 failure modes no scheduled maintenance has been proposed. Existing maintenance schedule for tilting tables indicates the maintenance action as and when required. Hence RCM based schedule specifies that additional preventive maintenance tasks need to be executed as compared to none initially. Cost incurred for this can be offset from the savings accrued from reduction in loss of production due to repetitive breakdowns. The methodology of RCM adopted in western industries cannot be applied as it is to Indian industries because of labour oriented nature, partially computerised information systems, non-availability of the information about cost of loss of production due to breakdown and age-reliability pattern of equipment, insufficient maintenance database. These problems can be overcome by development of sound MMIS, formulation of RCM review group and imparting suitable training to acquire the relevant skills in RCM. Thus RCM methodology can be applied to Indian industry for reduction of breakdowns as well as optimisation of preventive maintenance cost. This can further boost up the prospects of Indian industry to offer the products at globally competitive prices.

Reliability program for plant maintenance

With the increased emphasis on cost containment and reduction, the reliability of equipment has become an area of great concern. Many managers now see reliability-centered maintenance (RCM) as a method of gaining an advantage over the competition. What does reliability entail, and how can a RCM process be implemented? This article defines what a reliability process involves and illustrates how a reliability process was implemented at the Catawba, SC, USA, site of the Bowater Coated Paper Division. Both the successes and the growing pains experienced are discussed with thoughts on how the implementation could have gone smoother. The greatest benefits gained from the process are mentioned and plans for where to carry the process in the future are explored. The benefits of a successfully implemented reliability program have already been proven. In several process industries, such as refining and petrochemicals, reliability has been used to reduce maintenance budgets by up to 50%.

Reliability-Centered Maintenance

This paper provides an overview of the reliability-centered maintenance (RCM) engineering process. RCM is a unique tool used by reliability, safety, and/or maintenance engineers for developing optimum maintenance plans which define requirements and tasks to be performed in achieving, restoring, or maintaining the operational capability of a system or equipment. Implementing the RCM process requires the application of a decision logic that enables systematic analysis of failure mode, rate, and criticality data to determine the most effective maintenance requirements for maintenance-important items. It is through this process that the scheduled maintenance burden and support costs are reduced while sustaining the necessary readiness state. The RCM process is designed to focus engineering attention to the part level in a formal and disciplined manner leading logically to the formulation of a maintenance strategy and plan. RCM benefits include: *The development of high quality maintenance plans in less time and at lower cost. *The availability of a maintenace history for each system; one is able to correlate this experience with specific parts and their failure modes and criticalities. *The assurance that all maintenance-important parts and their failure modes and criticality are considered in the development of maintenance requirements. *The increased probability that the level and content of the maintenance requirement is optimally specified. *The basis for routine, on-line information exchange among the engineering staff and management even in a widely dispersed organization.