Why is it important?

This course is designed to build competency in RCM and to enhance the equipment reliability and overall plant productivity. It covers all the fundamentals of RCM that a suitably qualified professional would be expected to carry out during his duty starting with the first steps and building up to a fully functional advanced maintenance.

The aim of the course is to introduce the principles of RCM to individuals, who are exploring the potential of applying the RCM process within their business environment. The course will show, that RCM determines the best possible maintenance for your equipment, optimised according to the operating conditions on site. It will be discussed, that RCM can do this because the entire RCM process accommodates the following factors:

  • The overall environment and background conditions, in which you are using your equipment (i.e. its “operating context”)
  • What you want your equipment to do for you in respect of safety, the environment, output, product quality and customer service (i.e. its functions)
  • How much it matters, when your equipment fails (i.e. the failure consequences).

Course Outline

The training course will start with discussion in details the classical RCM seven questions about the asset or system under review, as follows:

  • What are the functions and associated performance standards of the asset in its present operating context?
  • In what ways does it fail to fulfil its functions?
  • What causes each functional failure?
  • What happens when each failure occurs?
  • In what way does each failure matter?
  • What can be done to predict or prevent each failure?
  • What should be done if a suitable proactive task cannot be found?

The course will continue with systematic and structured analysis of potential and functional machinery failures, hidden and evident failures, failure modes, effects and consequences, that play essential role in RCM maintenance type selection.

Optimal RCM selection of preventive/predictive maintenance will be discussed in details. The effective field-proven condition monitoring technologies (i.e. vibration, infrared thermography and wear debris), that should be used for RCM predictive maintenance, will be described in details. Finally, RCM ++ Software, Computerized Maintenance Management Systems (CMMS), that support RCM, will be demonstrated.

The training course will summarize the modern RCM methodology to select the most appropriate maintenance to deal with each type of asset failure in order to fulfil all the expectations of the owners.

Course Objectives

  • Optimal RCM based selection of preventive maintenance, predictive maintenance, run to failure maintenance and maintenance by redundancy/re-design
  • Effective use of condition monitoring technologies (i.e. vibration, infrared thermography and wear debris) for RCM
  • Demonstration of Computerized Maintenance Management Systems (CMMS) and RCM++ software
  • Systematic and structured analysis of the main Root Cause Analysis (RCA) best practice principles for RCM
  • Systematic and structured analysis of asset failure modes as root causes of functional failures
  • Systematic and structured analysis of the main RCA’s techniques for RCM
  • Practical application of guidelines for performing root cause analysis in complex electro-mechanical assets for RCM
  • Optimal performing RCA, using basic root cause analysis framework “eight disciplines problem solving”
  • Learning practical RCA for proactive maintenance via 17 industrial case studies
  • Systematic and structured analysis of the classical failure analysis for RCM
  • Learning practical failure analysis for proactive maintenance via 9 industrial case studies
  • Learning application of FMEA (Failure Mode and Effect Analysis) via theoretical analysis and industrial case studies
  • Learning practical methods of reduction of human root causes for RCM

Who Should Attend?

It is recommended that all maintenance, reliability, engineering and technical staff including leadership and management attend this training.

  • Plant Directors
  • Plant Managers
  • Maintenance Managers
  • Maintenance Superintendents and Foremen
  • Maintenance Engineers
  • Reliability and Safety Engineers
  • Storeroom Managers
  • Maintenance Supervisors/Coordinators
  • Maintenance Contract Administrators
  • Operator Supervisors and Operators
  • Maintenance Planners and Schedulers, who are directly and not directly involved in the plant maintenance activities, in machinery design, selection, installation, operation, inspection/condition monitoring, reliability and availability
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  • Introduction
  • Definitions of Maintenance and Reliability Centered Maintenance (RCM)
  • RCM: the Main Concepts and Seven Basic Questions
  • Build Systematic RCM Strategies for Your Organization:
  • Preventive/Time Based Maintenance
  • Predictive /Condition Based Maintenance
  • Run to Failure/Breakdown Maintenance
  • Proactive Maintenance
  • Maintenance by Redundancy
  • Opportunity Maintenance
  • Opportunistic Maintenance
  • Corrective Maintenance
  • Classification of Day to Day Maintenance
  • The Key People in RCM: a Planner, a Maintenance Supervisor, a Craftsman, Storeroom Personnel, an Operations Superintendent and Operator
  • Flow Chart of Maintenance Planning and Scheduling for RCM
  • Work Orders: Top Ten Essential Estimations
  • Work Orders: Industrial Case Studies
  • Maintenance Planning Principles for RCM
  • Maintenance Scheduling Principles for RCM
  • The Key RCM Metrics: Reliability, Mean Time Between Failures, Mean Time to Failure, the Instantaneous Failure Rate, Equipment Availability and Maintainability, Mean Time to Repair
  • Outsource RCM vs In-House RCM: What Works Best for Your Organisation?
  • Spare Part Management and Outsourcing for RCM
  • Cost Benefit Analysis for RCM
  • Life Cycle Cost Analysis for RCM
  • Functions: Primary and Secondary
  • Failures: Potential and Functional
  • The P-F Interval, the Net P-F Interval and Multiple P-F Intervals
  • Estimation of Optimum Maintenance Interval for Predictive and Preventive Maintenance
  • Estimation of Optimum Maintenance Interval for Predictive and Preventive Maintenance: Industrial Case Studies
  • The Operating Context
  • The Operating Context: Industrial Case Studies
  • Failure Modes
  • Hidden and Evident Failures
  • Failure Effects
  • Failure Consequences:
  • Hidden Consequences
  • Safety and Environmental Consequences
  • Operational Consequences
  • Non-Operational Consequences
  • Principles of Root Cause Analysis of Failures for RCM; an Approach of Six Root Causes
  • The Generic “Eight Disciplines Problem Solving” Technique for Root Cause Analysis
  • HAZOP (Hazard and Operability Study) for Root Cause Analysis
  • Guidance for Root Causes of Assets Failures
  • Planning Industrial Root Cause Analysis for RCM: 17 Industrial Case Studies (outlines are below)
  • Planning Failure Assessment for RCM: 9 Classical Steps
  • Failure Assessment for RCM: Industrial Case Studies
  • Six Patterns of the Instantaneous Failure Rate: Traditional View, Bathtub, Slow Aging, Best New, Random Failure and Worst New
  • Relationship Between the Failure Rate Pattern and Maintenance Type Selection for RCM
  • Failure Management for RCM: Proactive Maintenance and Default Maintenance
  • Proactive Maintenance:
  • On-Condition Predictive Maintenance
  • Preventive Repair Maintenance
  • Preventive Replacement Maintenance
  • Default Maintenance:
  • Failure-Finding Maintenance
  • Maintenance by Re-Design
  • Run-to-Failure Maintenance
  • Determining When to Prevent Failure and When to Allow Failure to Occur; Replace, Maintain or Refurbish: Optimally Planning Your Next Maintenance Action; Optimal Selection of Maintenance Type
  • Logic Diagram for Optimal Selection of Maintenance Type
  • Failure Mode and Effect Analysis (FMEA)
  • FMEA: Ranking Criteria and Industrial Case Studies
  • FMEA: Practical Session
  • Condition Monitoring for Predictive RCM
  • Fault Tree Analysis for Troubleshooting
  • Vibration Condition Monitoring: Basics and Main Technologies
  • Condition Monitoring by Wear Debris: Basics and Main Techniques
  • Condition Monitoring by Infrared Thermography: Basics and Main Techniques
  • Condition Monitoring for Condition Based Maintenance: 9 Industrial Case Studies
  • New International Condition Based Maintenance Standard for RCM
  • Design for Better Maintainability
  • RCM++ Software; Software Capabilities:
  • Equipment Selection for Maintenance Based on Selection Questions and Criticality Factors
  • Failure Effect Categorization
  • Selection of Maintenance Strategy and Tasks
  • Estimation of Optimum Preventive Maintenance Interval
  • Maintenance Task Packaging
  • Management of Corrective Maintenance Actions
  • Creation of Reports and Graphical Charts
  • Computerized Maintenance Management System; System Capabilities:
  • Management of Unplanned Works
  • Estimation of Planned versus Unplanned Works
  • Work Order Generation and Issue
  • Management of Maintenance Personnel Database
  • Gauge Calibration Management
  • Management of Condition Monitoring Data
  • Creation of Statistical Data and Reports
  • Estimation of Main Maintenance Metrics
  • Management of Maintenance Backlog for RCM
  • RCM: Industrial Case Studies
  • Human Errors in RCM; Reduction of Human Errors
  • The Main RCM Key Performance Indicators
  • Review: Learning Outcomes
  • Closing Comments

Root Causes of Failure for RCM: 17 Case Studies:

  • Maintenance of two stage vertical pumps
  • Maintenance of a vacuum exhauster
  • Maintenance of an engine turbocharger
  • Maintenance of a steam turbine
  • Maintenance of a primary air fan
  • Maintenance of two large fans
  • Maintenance of a turbine generator
  • Maintenance of a gas turbine gearbox
  • Maintenance of an oil pump bearing
  • Maintenance of a boiler fan bearing
  • Maintenance of an axial compressor
  • Maintenance of a motor bearing
  • Maintenance of a furnace
  • Maintenance of a fan
  • Maintenance of a turbine bearings
  • Maintenance of a gas turbine
  • Maintenance of a fan for power generation
Prof. Len Gelman
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Event Details
  • Start Date
    August 16, 2021 09:00
  • End Date
    August 18, 2021 17:00
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