WF74: Model-based RCM Analysis

Pre-Requisites

• A. RAM Module: access to the Reliability, Availability and Maintainability (RAM) Module is required to access Model-based RCM Analysis.
• B. MADE Model: For Model-based FMEA, a functional model containing items, functions and failure modes defined is required. Mission Profile, item failure distribution and its parameters, and MALDT are required for metrics (reliability and maintainability) calculations within RCM.
• C. FMEA excel: An excel can be imported in the absence of a MADE model (see WF77) to initiate an RCM analysis.

Detailed Steps

1. Define Task Taxonomy — MSG-3 and RCM II task taxonomies are available by default in Application Preferences > Modeling > Maintenance Type Terminology. Custom taxonomies can be created if required. The selected taxonomy is used across the MADE project.
2. Open Model-based RCM — select 'Model-based RCM' in the 'Analyses' tab of the menu bar.
3. Create an RCM analysis (see WF75) — define analysis name, description, RCM configuration, and methodology. RCM configuration lists predefined and customized workflows to identify significant function, categorize failure effect, evaluate tasks, and select applicable tasks. The methodology defines how the data the analysis is based on will be compiled — from MADE model or FMEA excel import. If FMEA import is used, a new system in MADE is created.
4. Identify Maintenance Significant Item (MSI) — refined by thresholding based on item properties (Critical, Safety, Mission Critical, Loss of system), Risk, Severity, Reliability, and Inherent Availability. (See WF19: Prepare RCM.)
5. Define Mission Context — define the operating context under which the MSI operates, and the expected performance criteria and reliability standards. (WF19)
6. Assess Functions — select a function of the chosen MSI to initiate the Significant Function (SF) logic workflow, designating it as significant or not by answering a series of questions. Only SFs are included in RCM analysis. (WF19)
7. Identify Failure Effect Category — categorize the effect of each failure mode of the SF by answering questions in the decision logic tree. (WF20: Perform RCM.)
8. Define & Evaluate Task — define all tasks to prevent the failure mode from occurring or to reduce the consequence to an acceptable level, and evaluate technical feasibility of each task. (WF20)
9. Task Selection — select task(s) by comparing cost and availability metrics (Mean Time Between Maintenance, Operational availability, Downtime). Selected task(s) are used for Reporting. (WF20)
10. RCM Analysis is performed for the MSIs within the selected system. From here, users can perform a Trade Study, Track Changes, Generate a Report, or Apply tasks to the System Model.

Screen-by-screen detail (from embedded screenshots)

• Step 1: Define Task Taxonomy — Preferences (Filtered) > Modeling > Maintenance Type Terminology: "Maintenance Type Terminology Sets" table (Current checkbox, Name, Description) — options: "MADE Default" (current, "The default Maintenance Type terminology as determined by the standard MADE taxonomy."), "MSG-3" ("Maintenance Type terminology that is relevant to the MSG-3 RCM methodology."), "RCM II" ("...relevant to the RCM II methodology."). Buttons: New, View, Copy, Import, Delete; Import/Export at bottom.
• Step 2: Open Model-based RCM — Main menu: Analyses > Model Based RCM (alongside Fault Tree, Response Paths, Connection Matrix, Common Mode Analysis, Critical Item Analysis, Criticality & Reliability Editor, Technical Budget Analysis, Failure Rate Prediction, Markov Analysis, RBD Analysis, Reliability Allocation Editor, Back-Fit RCM, Maintenance Cost Estimates).
• Step 3: Create an RCM Analysis — "Model-based RCM - Analysis 1 (PHMT)" view: left nav RCM Management > Significant Item Search, Mission Context, Functional Failure Analysis, Trade Study, RCM Summary, RCM Audit. "Basic" panel: Top Level (e.g. "[VS1] Vehicle System"), Indenture Limit (e.g. 3), Filter Settings (Filter type e.g. "Item Criticality", Threshold "Yes" for "Critical Item"), Search button. "Maintenance Significant Item Search Results" table (Item, Item Number, LCN, Risk, Severity, Reliability, Availability — e.g. Control Unit Risk 1.9521E-7, Coupling 1 Risk 6.5069E-7, Planetary Gearbox Rear Risk 6.5E-7). Right panel "Potential Maintenance Significant Items" (e.g. "Planetary Gearbox Rear" at 0% Completion).
• Step 4: Identify Maintenance Significant Items — Same Significant Item Search view; select items from the results table to add to "Potential Maintenance Significant Items".
• Step 5: Define Mission Context — "Mission Context" tab with sub-tabs "Operational Metrics" / "Functional Profile". "Mission Profile Overview" shows a Gantt-style timeline for the selected item (e.g. "Planetary Gearbox Rear") across mission Phase/Segments (Start-up, Acceleration, Cruise, Turning, Cruise 2 > Highway/Highway A1/Highway B2, Mountain Terrain, Deceleration, Shut-down) with durations and percentages. Note: mission profile syncs with the model, but the operational duration captured at analysis creation time is used for metric calculations; create a new version to use the latest duration. Below, "Maintainable Items" list and "Maintainable Item Context" tabs: Narratives, Phases and Segments, Operational Conditions, Environmental Conditions — with "Operating Context" and "Performance Standards" free-text fields.
• Step 6: Assess Functions — "Functional Failure Analysis" section: "Maintainable Item FMEA" table (Function/Failure Mode, ID, Completion, End Effect, Local Effects — e.g. "Store Mechanical - rotational Angular velocity" > "Low Mechanical - rotational Angular velocity due to cracking of t..."). Right panel "Decision Tree Workflow": "Safety/Environment Effect" question ("Does the loss of function have an adverse effect on safety or environment?" with narrative "Loss of gearbox can potentially result in accidents", Yes/No radio, Yes selected) leading to "Significant Function" result: "The function has been identified as a Significant Function" with narrative "This function is critical for the safe and reliable operation of the vehicle. Loss of this function can have severe consequences."
• Step 7: Identify Failure Effect Category — "Failure Effect Category" tab, "Failure Classification and Task Evaluation" sub-tab. "Decision Tree" panel with sequential questions: "1: Is Failure evident to Operating Crew?" (narrative "Failure is not hidden", Yes selected); "2: Does the failure effect safety?" (narrative "Loss of this function can have severe safety consequences", Yes selected); "5A: Lubrication/Servicing effective?" (narrative placeholder, No selected in example screenshot). Right panel "Failure Mode Details": Maintainable Item, Failure Mode, Failure Effect Category (e.g. "Evident Safety" — "Task required to assure safe operation"), Baseline P(f) / Adjusted P(f) (e.g. 2.566491E-2), Severity (e.g. "I"). Below, "Failure Effect Category Task" table (Name, ID, Type, Technical Feasibil..., Int..., Do..., Cost, As...).
• Step 8: Define and Evaluate Task — Continuing the Decision Tree: "5A: Lubrication/Servicing effective?" (Yes) adds Maintenance Task "Lubrication and Servicing"; "5B: Inspection/functional check effective?" (Yes) adds Maintenance Task "Inspection/Functional check". Right panel "Technical Feasibility Assessment": Applicability Criteria, Effectiveness Criteria - Safety, Effectiveness Criteria - Operational, Effectiveness Criteria - Economic (each Yes/No with narrative, e.g. "Yes, through early detection and timely corrective action"; "Yes, by addressing potential issue before it escalates."; "Yes, the cost of failure without preventative maintenance is significantly high"), and a "Technically Feasible" confirmation.
• Step 9: Task Selection — "Model-based RCM - Analysis 2 (Analyst 1)" > Trade Study tab. "Maintainable Items" list (e.g. "Coupling"). "Decision Summary": each task's item-level metrics used for trade studies. Table (Name, ID, Task Type, Cost, Downtime, Revised MTBM, Revised Ao, Revised FM Reliabil..., Assigned checkbox) — example: "Couple Mechanical - rotational Torque" > "Low Mechanical - rotational Torque due to circu..." > Inspection/Functio... (ID 001, Cost $135.00, Downtime 2 hr, Revised MTBM 9.14, Revised Ao 0.5664019) and Scheduled Discard (ID 002, Cost $300.00, Downtime 9 hr, Revised MTBM 1.05, Revised Ao 0.1161322), both Assigned (checked). "Calculate" button and "Summary Graph" bar charts for Cost, Downtime (Hours), Revised MTBM, Revised Ao.