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MADE Training > Session 5 > 5.4 Back-Fit RCM

Session 5.4: Back-Fit RCM

This session provides the hands-on training exercise walkthrough for Back-Fit RCM (complementary to the standalone Backfit RCM User Guide content already in this knowledge base — see backfit-rcm-* files for the full reference workflow/roadmap documentation).

Session 5.4 Outline

  • 5.4.1: Back-Fit RCM Background
  • 5.4.2: Back-Fit RCM Editor
  • 5.4.3: NAVSEA Road Map: Identify Failure Modes / Failure Assessment
  • 5.4.4: Maintenance Classification
  • 5.4.5: Maintenance Applicability
  • 5.4.6: Failure Consequences
  • 5.4.7: Maintenance Effectiveness
  • 5.4.8: Improve Task
  • 5.4.9: Proposed Maintenance
  • 5.4.10: Maintenance Association
  • 5.4.11: Back-Fit RCM Report

Discussion 5.4.1: Back-Fit RCM Background

  • Back-Fit RCM is based on a process described in USN SSC Handbook S9081-AB-GIB-010.
  • Back-Fit RCM processes involve:
    • Identifying Failure Mode / Faults
    • Failure Assessment
    • Maintenance Classification
    • Maintenance Applicability
    • Failure Consequences
    • Maintenance Effectiveness
    • Maintenance Task Improvement
    • Review Proposed Maintenance

Discussion 5.4.2: Back-Fit RCM Editor

The Back-Fit RCM Analysis editor consists of 3 main pages:

  1. Back-Fit Summary: For defining RCM time-span
  2. NAVSEA Road Map: Contains Back-Fit RCM analysis steps
  3. Maintenance Association: Summarises current & proposed maintenance actions; displays maintenance durations, downtimes, cost divergence

The Back-Fit Summary page contains 2 sections:

  1. Back-Fit RCM Time Span — Enter duration (time span) Back-Fit RCM analysis is performed over
  2. Proposed Maintenance Actions — Lists maintenance actions which address Failure Modes or Faults

Exercise 5.4.2: Back-Fit RCM Editor

Prerequisite: Set task taxonomy for the project.

  1. Navigate to Preferences > Application Preferences > Modeling > Maintenance Type Terminology
  2. Set MADE Default as Current
  3. Select Apply

To create a Back-Fit RCM Analysis:

  1. Right-click the Fuel Tank in the System Model/Project Explorer
  2. Select Back-Fit RCM
  3. Alternatively, select the Fuel Tank item and from the menu bar select Analyses > Back-Fit RCM

Select the Back-Fit Summary tab and enter the following Timespan and narrative:

  • Time Span: 1 Year
  • Narrative: Back-Fit RCM analysis covers the analysis of the Fuel Tank for the operational period from 2022 to 2023.

Discussion 5.4.3: NAVSEA Road Map: Identify Failure Modes

  • NAVSEA Road Map starts by identifying failure modes or faults of a component.
  • Existing maintenance actions (if available) are listed.

Exercise 5.4.3: NAVSEA Road Map: Identify Failure Modes

  1. In NAVSEA Road Map tab, select Enable Back-Fit RCM
  2. Select from the drop-down menu: Corroding of Lining due to Cavitation corrosion
  3. Under Existing Maintenance Actions select: 001 — Breakdown Maintenance

Discussion 5.4.3: Failure Assessment

Failure Assessment contains questions to determine:

  • Whether existing maintenance exists for the failure mode
  • Whether the Failure Mode occurs during the service life
  • Whether a maintenance action can be created to address the failure path

Displays existing maintenance actions associated to the component. Recommended action with a link displayed at the bottom of page after the questions are answered — e.g. "Yes" to existing maintenance actions and existence of age degradation will cause Back-Fit RCM to recommend continuing to classify the type of maintenance task.

Exercise 5.4.3: Failure Assessment

  1. Select the Failure Assessment tab
  2. Read Question 1 (Is there an existing Maintenance Action?) and select response: Yes
  3. Select existing maintenance action from drop down menu: 001 — Breakdown Maintenance
  4. Read Question 2 (Does Failure Mode occur...) and select response: Yes
  5. Enter comment: Item Failure diagram — sourced from maintenance data.
  6. Review Recommended Action: Continue Analysis — "Go to step 3. Classification" can be used to proceed to next tab

Discussion 5.4.4: Maintenance Classification

This page is used to determine which major category the maintenance action falls under. Main categories include:

  • Condition-Directed (CD)
  • Time-Directed (TD)
  • Failure Finding (FF)
  • Servicing (S)
  • Lubrication (L)

Selecting a maintenance type category will generate a link at the bottom of the page — e.g. Selecting Time-Directed maintenance will prompt the user to continue to Step 4: Applicability.

Exercise 5.4.4: Maintenance Classification

  1. Select 3. Classification Tab
  2. Select Failure Finding for Maintenance Type Task

Note: Recall the existing maintenance action is a Breakdown Maintenance.

Discussion 5.4.5: Maintenance Applicability

The Maintenance Applicability page contains questions to determine:

  • Whether the existing maintenance action is applicable
  • Whether the existing maintenance action can be modified in order to meet applicability requirements

The page displays existing maintenance actions associated to the component. Recommended action with a link is displayed at the bottom of page after the questions are answered — e.g. Yes to the applicability of existing maintenance actions will cause Back-Fit RCM to recommend continuing to describe the consequences of the failure mode occurring.

Exercise 5.4.5: Maintenance Applicability

  1. Select 4. Applicability tab
  2. Review applicability criteria
  3. Select: Yes (Existing Maintenance is applicable)
  4. Enter Narrative: Meets Applicability Criteria.
  5. Under Recommended Action, select Go to step 5: Failure Consequence

Discussion 5.4.6: Failure Consequences

The Failure Consequences page aims to classify the nature of the selected failure mode into the following categories:

  • Safety/Environmental
  • Operational Performance
  • Others

A recommended action with a link is displayed at the bottom of the page after a failure consequence type is selected — e.g. Selecting Operational Performance as a failure consequence of blockage of the primary fuel filter due to silting will cause Back-Fit RCM to recommend continuing to describe the effectiveness of the existing maintenance.

Exercise 5.4.6: Failure Consequences

In the Failure Consequence tab:

  1. Select: Operational Performance
  2. Narrative: Cavitation corrosion in Fuel Tank will prevent fuel flow.
  3. Select link: Go to step 6: Effectiveness

Discussion 5.4.7: Maintenance Effectiveness

The page displays existing maintenance actions associated to the component. A recommended action with a link is displayed at the bottom of the page after the questions have been answered — e.g. If the risk of failure is not reduced to an acceptable level (No), leads to the next question activating. A Yes response to whether the existing maintenance action can be improved will show a link to the final page.

The Maintenance Effectiveness page contains questions to determine:

  • Whether the existing maintenance reduces the risk of failure to an acceptable level (Probability of Failure × Severity of Failure)
  • Whether the existing maintenance action can be improved to demonstrate its effectiveness

Exercise 5.4.7: Maintenance Effectiveness

  1. Review Effectiveness criteria — Does it reduce the probability of failure to an acceptable level?
  2. Select: Yes (Existing Maintenance is Effective)
  3. Enter Narrative: Effectiveness based on FMECA documentation.
  4. Select Go to step 7: Improve Task

Discussion 5.4.8: Improve Task

The Improve Task page allows the user to decide whether the current maintenance task can be improved or to override the recommendations put forward, e.g. modify the existing maintenance task. A narrative box is provided to enable the user to explain the motive behind the decision. A link is displayed at the bottom of the page after a decision has been selected.

Exercise 5.4.8: Improve Task

  1. Review list of Maintenance Action Improvements
  2. Select: No Change (Existing Maintenance is Effective)
  3. Enter Narrative: Maintenance Action is currently sufficient for selected failure.
  4. Select Go to step 8: Propose Maintenance

Discussion 5.4.9: Proposed Maintenance

  • The page displays a section to create a proposed maintenance action.
  • The Maintenance comparison table shows the differences between current maintenance and proposed maintenance if differences are present.
  • The Proposed Maintenance page shows the recommended action based on the answers selected in previous pages, which can include:
    • No Change
    • Modify task
    • Delete task
    • Add New task
    • Re-design

Exercise 5.4.9: Proposed Maintenance

  1. Enter Proposed Maintenance Narrative: Current Maintenance Action is sufficient for Fuel Tank fault.

Discussion 5.4.10: Maintenance Association

The Maintenance Association page summarises:

  • Faults or failure modes that have been analysed
  • Current and proposed maintenance actions
  • Comparison between the two maintenance actions (if applicable)

The page also displays in a graph format:

  • Meantime between Maintenance (MTBM)
  • Cost
  • Downtime deltas

Discussion 5.4.11: Back-Fit RCM Report

The Back-Fit RCM Report summarises the Back-Fit RCM analysis into the following sections:

  • Component Summary: Shows a summary of changes in MTTF, durations and costs.
  • Maintenance Action Summary: Compares existing maintenance to proposed maintenance and the duration and cost differences between the two.
  • Component Details: Specific breakdown of each failure path in terms of frequency, durations and costs; a summary of responses to all NAVSEA questions answered; displays the maintenance action comparison table; displays the current and proposed maintenance action details e.g. tasks, personnel, costs, durations, etc.

Exercise 5.4.11: Back-Fit RCM Report

  1. Select Reports > Report Wizard from the main menu
  2. Select Back-Fit RCM Report
  3. Select Next then select the check box for maintainable items to include in the report
  4. Select Generate to generate the Back-Fit RCM report

Session 5.4 Summary

  • 5.4.1: Back-Fit RCM Background
  • 5.4.2: Back-Fit RCM Editor
  • 5.4.2/5.4.3: NAVSEA Road Map: Identify Failure Modes
  • 5.4.3: Failure Assessment
  • 5.4.4: Maintenance Classification
  • 5.4.5: Maintenance Applicability
  • 5.4.6: Failure Consequences
  • 5.4.7: Maintenance Effectiveness
  • 5.4.8: Improve Task
  • 5.4.9: Proposed Maintenance
  • 5.4.10: Maintenance Association
  • 5.4.11: Back-Fit RCM Report

Session 5 Overall Summary

  • 5.1: Maintenance Cost Estimates analysis
  • 5.2: Maintenance Actions
  • 5.3: Reliability Centered Maintenance (Model-Based)
  • 5.4: Reliability Centered Maintenance (Back-Fit RCM)

Source: Local MADE 3.9.1 installation: com.phm.made.help.plugin/documents/help/pdf/MADE Training Session 5.pdf · retrieved 2026-07-09