Session 5.3: Reliability Centered Maintenance

Session 5.3 Outline

• 5.3.1 Maintenance Task Taxonomy
• 5.3.2 Contributor Roles
• 5.3.3 RCM Management Editor
• 5.3.4 Create a RCM Analysis using Model-Based FMEA
• 5.3.5 Contributor Profiles
• 5.3.6 Model-Based FMEA — Analysis Overview
• 5.3.7 Model-Based FMEA - Significant Item Search
• 5.3.8 Model-Based FMEA - Mission Context
• 5.3.9 Model-Based FMEA - Functional Failure Analysis
• 5.3.10 Model-Based FMEA - Evaluate Failure Mode
• 5.3.11 Model-Based FMEA - Defining Maintenance Actions
• 5.3.12 Model-Based FMEA - Trade Study
• 5.3.13 Model-Based FMEA - RCM Summary
• 5.3.14 Model-Based FMEA - RCM Audit
• 5.3.15 Model-Based FMEA - RCM Report
• 5.3.16 Create a RCM Analysis using FMEA Excel Data

Discussion 5.3: Reliability Centered Maintenance

What is the difference between Back-Fit & Classic RCM? When are they used?

Classic RCM: A process that develops, analyses and documents requirements to develop a maintenance program.

• Environment of uncertainty
• Limited operating data

Back-Fit RCM: A process that confirms assumptions when the original maintenance program was developed once sufficient operating data exists.

• Validates existing maintenance requirements
• Recommends changes where appropriate

MADE includes both Classic RCM & Back-Fit RCM:

• Classic RCM (called Model-Based RCM in MADE) is referenced from SAE JA-1011/12, RCM II, and MSG3
• Back-fit RCM is based on a process described in USN SSC Handbook S9081-AB-GIB-010, MIL-STD-3034

Key functionalities include:

• Flexible Analysis Creation: Supports both Model-Based FMEA and FMEA excel import (FMEA datasets from Excel) workflows for creating RCM analyses.
• MSG-3, RCM II Decision Logic: Pre-defined and customizable workflows for consistent failure mode assessment and maintenance decision-making
• Maintenance Action Evaluation: Define and assess maintenance tasks, including feasibility, costs, and effectiveness, with structured decision support.
• Trade Studies: Compare maintenance strategies against metrics like cost, downtime, reliability, and availability to identify optimal actions.
• Interactive Metrics Visualization: Charts and summaries displaying baseline, revised, and delta metrics for reliability and availability.
• RCM Audit Tab: Maintain a detailed chronological log of all changes, searchable by contributors for traceability.

Exercise 5.3 Prerequisites

Modify the parameters of Planetary Gearbox Rear:

1. Navigate Project Explorer > Vehicle System > Driveline
2. Select Planetary Gearbox Rear and navigate to Properties
3. In General tab, set the Critical Item flag
4. In Reliability tab, change MTTF to 50 hours

Set Regular Trip as the active mission profile in the Mission Profile Definition:

1. Navigate Modeling > Mission Profile Definition
2. Right-click Regular Trip and select Set as Active Mission Profile

Discussion 5.3.1: Maintenance Task Taxonomy

MADE allows creating and maintaining maintenance task taxonomies which are used across the software. Three taxonomy sets are available by default:

• MSG-3
• RCM II
• MADE Default

Exercise 5.3.1: Maintenance Task Taxonomy

1. Navigate to Preferences > Application Preferences > Modeling > Maintenance Type Terminology
2. Set MSG-3 as Current
3. Select Apply/OK

Discussion 5.3.2: Contributor Roles

Contributor roles define the responsibilities of each contributor participating in the RCM process. These roles are maintained at the application level.

Exercise 5.3.2: Contributor Roles

1. Navigate to Preferences > Application Preferences
2. Expand RCM and select Contributor Roles
3. Select the icon to create new contributor role
4. Enter:
   • Name: Reliability Engineer
   • Description: Evaluates failure modes and recommends maintenance strategies to enhance system reliability, safety, and efficiency.
5. Select Save
6. Select OK

Discussion 5.3.3: RCM Management Editor

• Lists all RCM Analyses conducted
• Centralized dashboard to create, edit, update, and delete analyses, with key details at a glance

Exercise 5.3.3: RCM Management Editor

1. Select Analyses > Model-Based RCM from the main menu

Discussion 5.3.4: Create a RCM Analysis using Model-Based FMEA

The analysis creation provides the ability to choose:

• RCM Configuration: Sets the decision trees for determining the Significant Functions of the Maintainable Items and the Failure Effect Categories of the Failure Modes of the Significant Functions. MSG-3 and RCM II configurations are available OOTB.
• Workflow Type:
  • FMEA data import workflow allows import — items, functions, failure modes, criticality and reliability properties are ingested into MADE as a new system.
  • Model-Based FMEA takes data from the model and generates the report based on user selection for the basis of the analysis.

Note: A configuration is selected at the time of analysis creation and cannot be changed afterwards.

Exercise 5.3.4: Create a RCM Analysis using Model-Based FMEA

To create an RCM Analysis, in the RCM Management page:

1. Select the icon to open the Create RCM Analysis wizard
2. Enter the analysis name: Analysis 1
3. Enter comment: The following analysis is based on the Regular Trip mission for maintenance costs. The main candidate is the Planetary Gearbox Rear as this is modelled for training purposes.
4. Select MSG-3 as the RCM configuration
5. Select Model-Based FMEA as the workflow type
6. Select CA (MIL-STD-1629A, Quantitative Standard) as FMEA analysis type
7. Select Next to access analysis options
8. Select System as level of analysis
9. Select FCM as a propagation method
10. Set Vehicle System end effect and system
11. Select PHMT 1629A Criticality as the criticality profile
12. Select the icon to set the criticality threshold
13. Select No Criticality Threshold as criticality threshold
14. Select Generate to generate the FMEA data
15. Review the generated FMEA
16. Select the add icon to add contributor(s) involved in conducting the analysis

Discussion 5.3.5: Contributor Profiles

• RCM provides functionality to create and manage contributor profiles associated with the RCM process, with clearly defined role assignments for each contributor.
• All changes made in the analysis are logged against the selected contributor for detailed audit tracking.

Exercise 5.3.5: Contributor Profiles

1. Select the add icon
2. Enter:
   • Name: PHMT
   • Company: PHM Technology
   • Title: Engineer
3. Select Reliability Engineer as Role using the drop-down
4. Select Save to complete creating a new contributor
5. Select to set the contributor as the current contributor

Discussion 5.3.6: Model-Based FMEA — Analysis Overview

The Analysis Overview tab is named after the name of the analysis. It features the ability to view general information about the analysis, create and assign Contributors, review Mission Profile, and add documents and images related to the analysis.

For Model-Based FMEA, the active mission profile is assigned to the analysis by default.

Discussion 5.3.7: Model-Based FMEA - Significant Item Search

• Each tab within the analysis forms part of the workflow.
• In the Significant Items Search tab, Potential Maintenance Significant Items (MSI) are selected.
  • The search function allows adjusting the top level and applying multiple threshold criteria such as Item Criticality, Failure Criticality, Baseline Reliability, and Baseline Inherent Availability to filter items within the system. By default, the top level is set to the system.
• Functions and Failure Modes defined for the Potential MSI qualify for further RCM assessment.

Exercise 5.3.7: Model-Based FMEA - Significant Item Search

1. In Filter Settings section: Select Filter as Item Criticality
2. Select the settings icon; Enable Critical Items checkbox
3. Select OK
4. Click Apply to view/apply the filter
5. Select the Planetary Gearbox Rear component from the search results
6. Click Add to add Planetary Gearbox Rear as Potential Maintenance Significant Item for the analysis

Discussion 5.3.8: Model-Based FMEA - Mission Context

Mission Context tab shows the Functional Profile for the system and mission phases/segments, operational conditions, environmental conditions, duty cycle, and duration of operation for the Maintainable Item to carefully examine the mission profile information for defining the operating context under which the item operates and establishing performance criteria to customize RCM strategies.

Note: Mission Profile information is not displayed for excel import FMEA and mission profile groups.

Exercise 5.3.8: Model-Based FMEA - Mission Context

1. From the Maintainable Items table select: Planetary Gearbox Rear
2. Add Operating Context: The gearbox operates under a regular trip mission profile, environmental factors include ambient temperatures ranging from -40°C to 55°C and relative humidity levels up to 90%. It is exposed to potential vibration and shock loads due to vehicle operation.
3. Add Performance Standards: Withstanding a minimum pressure threshold without deformation or leakage. Demonstrating damage under standard operating conditions.

Discussion 5.3.9: Model-Based FMEA - Functional Failure Analysis

• The Functional Failure Analysis tab lists the functions and failure modes of the Maintainable Item and applies the decision logic from the selected RCM configuration to evaluate these functions.
• The FMEA table is useful to review FMEA data while assessing the functions.
• Failure modes associated with functions deemed Significant qualify for further RCM assessment.

Note: The decision tree is incorporated from NAVAIR.

Exercise 5.3.9: Model-Based FMEA - Functional Failure Analysis

1. In the Maintainable Item section select: Planetary Gearbox Rear
2. Under Function/Failure Mode select: Store Mechanical - rotational Angular velocity
3. For the Safety/Environment Effect question select: Yes
   • Add narrative: Loss of gearbox can potentially result in accidents
4. Under Significant Function:
   • Add narrative: This function is critical for the safe and reliable operation of the vehicle. Loss of this function can have severe consequences.

Discussion 5.3.10: Model-Based FMEA - Evaluate Failure Mode

• The failure mode evaluation includes identifying failure consequences by answering the questions in the decision logic tree from MSG-3 (the selected RCM configuration).
• Allocate, define, and assess the feasibility of the maintenance tasks that will reduce the impact of the failure mode.

Exercise 5.3.10: Model-Based FMEA - Evaluate Failure Mode

1. Under Function/Failure Mode double-click: Low Mechanical - rotational Angular velocity due to cracking of the Planetary Gearbox Rear as a result of impact fatigue caused by impact loads resulting in Low Mechanical - rotational Angular velocity (Driveline) and Low Mechanical - rotational Angular velocity (Vehicle System)

To identify the failure effect category of the failure mode:

• In Task Evaluation Decision Tree: Is Failure evident to Operating Crew?
  • Response: Yes; Narrative: Failure is not hidden
• In Task Evaluation Decision Tree: Does the failure effect safety?
  • Response: Yes; Narrative: Loss of this function can have severe safety consequences

To identify the maintenance actions suitable to address the failure mode:

• Lubrication/Servicing Effective? — Response: Yes; Narrative: Moving parts or mechanisms requiring lubrication
• Inspection/functional check effective? — Response: Yes; Narrative: Regular inspections ensure early detection of issues
• Restoration effective? — Response: Yes; Narrative: Scheduled repair helps to maintain structural integrity
• Discard Effective? — Response: No
• Combination of tasks effective — Response: Yes; Narrative: Tasks can be done as per the defined interval. Task grouping isn't essential.

Discussion 5.3.11: Model-Based FMEA - Defining Maintenance Actions

• Maintenance actions address failures in a maintainable item. This can be done by addressing hidden failures, preventing a failure before it occurs by maintaining an item or constantly monitoring it based on its condition, treating failures after they have occurred, or changing the item's design to reduce failures and increase reliability.
• These actions estimate maintenance/inspection interval, downtime, and cost.
• The selected RCM configuration determines the maintenance action types.
• In addition to the maintenance actions generated from the decision tree, additional maintenance actions can be added.
• The set of available tasks is constrained by the task taxonomy configured in section 5.3.1.

Exercise 5.3.11: Model-Based FMEA - Defining Maintenance Actions

Inspection/Functional check tab:

• Failure Mode Metrics: Effectiveness Factor: 0.05; Revised P(f) Narrative: Revised P(f) is acceptable
• Feasibility Metrics: P-to-F Factor: 0.2 (P-to-F Interval calculated as 10 hours); P-to-F Interval Narrative: Vibration or shuddering during gear changes or acceleration.
  • Add a Symptom: Symptom as Sputtering of engine; Monitoring Technique: Vibration Analysis
• Cost Metrics: Cost of Failure: $20; Cost Narrative: Cracks in the gearbox casing can breach the sealed environment leading to spillage.; Cost of Detection: $30; Cost Narrative: Expenses for monitoring equipment
• Maintenance Action Details: Action ID: 002; Action Name: Inspection/Functional check; Location of Maintenance: Local Depot; Maintenance interval: 50 hours; Inspection interval (Direct Entry): 1 hour

Maintenance Task and Personnel table:

ID	Task Name	Downtime	Duration	Rate	# Personnel
001	Removal	Yes	0.5	$100.00	1
002	Service maintainable item	Yes	0.5	$100.00	1
003	Lubricate maintainable item	Yes	0.5	$100.00	1
004	Reinstallation	Yes	0.5	$100.00	1
005	Testing Approval	Yes	0.5	$100.00	1 (Supervisor)
006	Administration	No	1	$100.00	1 (Clerk)

Maintenance Equipment and Consumables:

Item ID	Item Name	Cost	Quantity
001	Service Toolkit	$150.00	1

Inspection Tasks and Personnel:

ID	Task Name	Downtime	Duration	Rate	# Personnel
001	Inspect maintainable item	Yes	1.0	$100.00	1
002	Perform functional test on maintainable item	No	1.0	$100.00	1

Technical Feasibility Assessment section:

• Applicability Criteria: Yes — narrative: Reduced resistance is detectable through sensor and the interval is reasonably consistent
• Effectiveness Criteria – Safety: Yes — narrative: Yes, through early detection and timely corrective action
• Effectiveness Criteria – Operational: Yes — narrative: Yes, by addressing potential issue before it escalates.
• Effectiveness Criteria – Economic: Yes — narrative: Yes, the cost of failure without preventative maintenance is significantly high

Restoration (Scheduled - Repair) maintenance tab:

• Failure Mode Metrics: Effectiveness Factor: 0.05; Revised P(f) Narrative: Revised P(f) is acceptable
• Cost Metrics: Cost of Failure: $500; Cost Narrative: Loss of availability penalty
• Maintenance Action Details: Action ID: 003; Action Name: Restoration; Description: Perform a scheduled repair of the maintainable item.; Location of Maintenance: Field; Maintenance interval (Direct Entry): 30 minutes

Maintenance Task and Personnel:

ID	Task Name	Downtime	Duration	Rate	# Personnel
001	Remove maintainable item	Yes	1.0	$100.00	1
002	Repair maintainable item	Yes	2.0	$100.00	1
003	Reinstall maintainable item	Yes	1.0	$100.00	1
004	Test maintainable item	Yes	1.0	$100.00	1

Maintenance Equipment and Consumables:

Item ID	Item Name	Cost	Quantity
001	Repair Toolkit	$750.00	1

Technical Feasibility Assessment: Applicability, Safety, Operational, Economic all Yes.

Lubrication and Servicing (Scheduled - Service) maintenance tab:

• Failure Mode Metrics: Effectiveness Factor: 0.05; Revised P(f) Narrative: Revised P(f) is acceptable
• Cost Metrics: Cost of Failure: $0; Cost Narrative: Scheduled maintenance, no failure cost involved.
• Maintenance Action Details: Action ID: 001; Action Name: Lubrication and Servicing; Description: Perform lubrication and servicing activities on the maintainable item.; Location of Maintenance: Field; Maintenance interval: 20 minutes

Maintenance Task and Personnel:

ID	Task Name	Downtime	Duration	Rate	# Personnel
001	Remove maintainable item	Yes	1.0	$100.00	1
002	Service & lubricate maintainable item	Yes	1.0	$100.00	1
003	Reinstall maintainable item	Yes	0.5	$100.00	1
004	Test maintainable item

Maintenance Equipment and Consumables:

Item ID	Item Name	Cost	Quantity
001	Service Toolkit	$750.00	1

Technical Feasibility Assessment: Applicability, Safety, Operational, Economic all Yes.

Discussion 5.3.12: Model-Based FMEA - Trade Study

• Trade Study tab allows the comparison of important characteristics for all completed maintenance actions.
• Metrics compared: Task Type, Cost, Downtime, Revised MTBM, Revised Ao

Note: Each task calculates item-level metrics using only its own data to support effective trade studies.

Exercise 5.3.12: Model-Based FMEA - Trade Study

1. Select Trade Study tab
2. Select Planetary Gearbox Rear
3. Click Calculate
4. Review the metrics
5. Set as Assigned: Inspection/Functional check, Lubrication and Servicing

Discussion 5.3.13: Model-Based FMEA - RCM Summary

• The RCM Summary provides a detailed overview of all items included in the analysis, their significant functions, failure mode effects category, assigned maintenance tasks, and criticality information.
• It also allows customization of column headers to display specific information and apply the maintenance actions to the model.

Exercise 5.3.13: Model-Based FMEA - RCM Summary

1. Select RCM Summary tab
2. Under Preferences, select:
   • Filter: Show Potential Maintenance Significant Items Only
   • Indenture: Tasks
   • Column Preference: System Performance Metrics
3. Click Apply
4. To apply the tasks to the model, click Apply to Model
5. To view the Maintenance Actions exported to the model: select the Planetary Gearbox Rear component in the Project Explorer, and from the drop-down menu select the Maintenance Actions option

Discussion 5.3.14: Model-Based FMEA - RCM Audit

• Completion status shows status of all functions for maintainable items, including failure modes and their categories for the significant functions that are updated dynamically based on the answers in the decision trees for function and failure mode assessment.
• The Audit log lists all the changes made within the analysis for traceability.

Exercise 5.3.14: Model-Based FMEA - RCM Audit

1. In the Workflow — Completion Status section, select the export icon to export analysis status as .png
2. In the Audit Log section:
   • double-click or right-click the first event log to add narrative: Narrative for demo purpose
   • select export icon to export the log as .csv

Discussion 5.3.15: Model-Based FMEA - RCM Report

The RCM Analysis Report provides a detailed report of the RCM Analysis in PDF, Excel, and CSV formats. Generating the report in CSV format provides the flexibility to choose the information that needs to be included, such as Mission Profile, Maintenance Significant Items, Significant Functions, Failure Modes, Criticality Assessment, and Tasks.

Exercise 5.3.15: Model-Based FMEA - RCM Report

1. Select Reports > Report Wizard from the main menu
2. Select PDF
3. Select RCM Analysis Report
4. Select Next
5. Select Analysis 1
6. Select Generate

Discussion 5.3.16: Create a RCM Analysis using FMEA Excel Data

• RCM provides the capability to import FMEA data from Excel.
• The FMEA data import workflow supports the ingestion of Maintainable Items, Functions, Failure Modes, and associated Reliability and Criticality parameters, enabling their direct use in RCM analysis.
• As part of the import process, the workflow automatically creates a new system that includes the items, functions, failure modes, and the corresponding reliability and criticality datasets sourced from the excel file.
• Execution of this workflow requires prior configuration of a data mapping, which defines the relationship between excel data fields and the RCM data model.

Note: FMEA excel and configuration files are required for this section.

Exercise 5.3.16: Create a RCM Analysis using FMEA Excel Data

1. Navigate back to RCM Management tab
2. Select the icon to open the Create RCM Analysis wizard
3. Enter:
   • Analysis name: Analysis 2
   • Description: Analysis created using FMEA excel import for training purposes.
4. Select MSG-3 as RCM Configuration
5. Select FMEA data import as Workflow Type
6. Select Next
7. Enter System Name: Landing Gear (FMEA Import)
8. Browse and select the sample FMEA excel
9. Select the icon to browse and select the configuration file
10. Select the icon to review the imported FMEA information
11. Select the add icon to add contributor(s) involved in conducting the analysis

Note: Any errors identified during the import will be flagged and must be rectified before proceeding further.

To create a Contributor Profile:

1. Select the add icon
2. Enter: Name: PHMT; Company: PHM Technology; Title: Engineer
3. Select Reliability Engineer as Role using the drop-down
4. Select Save to complete creating a new contributor
5. Select to set the contributor as the current contributor

Note: Once the analysis is created, the remainder of the RCM process follows the same steps as when it is created using the MADE model.

Session 5.3 Summary

• 5.3.1 Maintenance Task Taxonomy
• 5.3.2 Contributor Roles
• 5.3.3 RCM Management Editor
• 5.3.4 Create a RCM Analysis using Model-Based FMEA
• 5.3.5 Contributor Profiles
• 5.3.6 Model-Based FMEA — Analysis Overview
• 5.3.7 Model-Based FMEA - Significant Item Search
• 5.3.8 Model-Based FMEA - Mission Context
• 5.3.9 Model-Based FMEA - Functional Failure Analysis
• 5.3.10 Model-Based FMEA - Evaluate Failure Mode
• 5.3.11 Model-Based FMEA - Defining Maintenance Actions
• 5.3.12 Model-Based FMEA - Trade Study
• 5.3.13 Model-Based FMEA - RCM Summary
• 5.3.14 Model-Based FMEA - RCM Audit
• 5.3.15 Model-Based FMEA - RCM Report
• 5.3.16 Create a RCM Analysis using FMEA Excel Data