Modified full RCM program process by 0VzlRHK

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									                                                                          FULL RCM PROGRAM TASK SEQUENCE FLOWCHART
              STEP 1
           Develop/update
          RCM Program Plan




   STEP 2
  STEP 2A                     STEP 2
                             STEP 2B                                             STEP 7                                                STEP 9

     Current                 New                                                  Perform
Equipment Design       Equipment Design                   Functional Significance Determination for each function                         Identify
                        Recommended                                                                                              all failure modes and
                                                                                                                                   their failure effects
                                                                                                                                 (Local, Next Higher &
                                                        FUNCTIONAL SIGNIFICANCE DETERMINATION LOGIC                                    End Effects)
                                               Does the loss of function have an adverse effect
              STEP 3                                      on safety or environment?                    Yes
                                                                                                                                      STEP 10                        SSWG
                                                                          No
               Complete                        Does the loss of function have an adverse effect
          End Item & Level 1                                    on operations?                                                           Select               System Safety input to
                                                                                                       Yes
             Breakdown                                                                                                           Severity Class for the       Severity Classification
                                                                          No
                                                                                                                                    failure mode                 of failure modes
                                               Does the loss of function have an adverse effect
              STEP 4                                            on economic?                           Yes
                                                                                                                                       STEP 11                     STEP 13
                                                                          No
              Complete
          Level 2 Breakdown                   Is this function protected by an existing PM task?                                       Complete               Calculate or estimate
                                                                                                       Yes                             FMECA.                  failure distribution
                                                                          No
                                                                                                                                                                      curve
              STEP 5                                   NON-SIGNIFICANT FUNCTION                    SIGNIFICANT FUNCTION
                                                                                                                                Select a failure mode for
                                                                                                                                  RCM Analysis and                 STEP 14
              Complete                                                                                                                  perform
            Levels 3 and 4                                                                                                        STEPS 11 thru 23
             Breakdowns
                                                        Steps 8 and up steps are not to be                   STEP 8                                         Calculate or estimate time
                                                           performed for this function.                                                                           to first failure
                                                                                                                                      STEP 12
              STEP 6                                    Perform STEP 7 for next function.                     Identify
                                                                                                      all functional failures
                                                                                                       and Compensating            Collect failure and
                Identify
                                                                                                            Provisions                  test data
             all functions


                                          RCM ANALYSIS TASKS                    RELIABILITY ANALYSIS

                                          IMPLEMENTATION TASKS                  REDESIGN / CIP TASKS

                                          OPERATIONS                            OTHER EVENTS                                                                            A

                                          FMECA TASKS                           FEEDBACK TASKS



                                                                                                                                                                                         2-7
                                                                                                                                                                                         2 – 8 (Blank)
                                                                                FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

                                                                             STEPS 18                                                                                                A
                                                                              Answer
                                                                 failure consequences questions.
                                                                             (MODULE 10)

                    Is the functional failure or effect of the failure mode, on its own, evident to the operator while performing normal duties?
                                                                                                                                                                                STEP 15

                                                YES                                                  NO
                              EVIDENT                                                                                         HIDDEN                                       Will this failure mode
Does the failure mode cause a function loss or secondary damage that                    Does the occurrence of the hidden failure mode in combination with a second         happen within the          NO
 could have an adverse effect on operating safety or lead to serious                    failure / event cause a function loss or secondary damage that could have an        service life of the
                      environmental violation?                                          adverse effect on operating or lead to serious environmental violation safety?          equipment?

                                                           NO                                       NO                                                                         YES
       YES                                                                                                                                                YES                                Steps 16 and up steps are not to
                                                                                                                                                                                               be performed for this failure
         Evident                                    Evident                                         Hidden                                           Hidden                                              mode.
  Safety / Environment                        Economic / Operational                          Economic / Operational                          Safety / Environment
                                                                                                                                                                                                      GO TO STEP 23

                              STEP 18A                                                                                      STEP 18A
                                                                   STEPS 18A THRU 18F
                                                                         REQUIRED                                                                                               STEP 16
                              Develop                                INFORMATION (as                                         Develop
                              PHM task                             applicable, not all data                                 PHM task                                     Determine whether failure
                                                                    required for all FM’s)                                                                                 has PF, wear out, or
                              STEP 18B                                                                                      STEP 18B                                        random type failure
                                                                                                                                                                              characteristics
                                Develop                                                                                     Develop
                    Servicing / Lubrication PM task                 Description for each task                   Servicing / Lubrication PM task
                                                                                                                                                                                STEP 17
                              STEP 18C                                                                                      STEP 18C
                                                                               Determine
                                                                        Number of OC or PHM
                              Develop                                  tasks required during PF                             Develop                                       Determine or estimate
                         On-Condition PM task                            interval to meet Pacc                         On-Condition PM task                                 PF condition, PF-FF
                                                                                                                                                                          interval or wear out/life
                              STEP 18D                                                                                     STEP 18D                                               limit age
                                                                              Determine
                               Develop                                 PM intervals for all tasks                            Develop
                          Hard Time PM task                                                                             Hard Time PM task

                                                                            Determine                                       STEP 18E
                              STEP 18E
                                                                       Single task total man-
                                                                          hours and cost
                                                                                                                             Develop
                               Develop
                                                                                                                           Other Action
                             Other Action

                                                                                                                            STEP 18F


                                                                                                                            Develop
                                                                                                                    Failure Finding PM task
   B                                                         C                                      D                                                           E


                                                                                                                                                                                                                        2-7
                                                                                                                                                                                                                        2 – 8 (Blank)
                                                                                    FULL RCM PROGRAM TASK SEQUENCE FLOWCHART


            B                                                     C                                    D                                                        E



                                                                                             STEP 19                                                                                             STEP 23
          STEP 19                               STEP 19                                                                              STEP 19

                                                                                                                                                                                                   Repeat
        Determine costs                      Determine costs                              Determine costs                         Determine costs
                                                                                                                                                                                          STEPS 11 thru 23 until all
      associated with each                 associated with each                         associated with each                    associated with each
                                                                                                                                                                                          FM(s) have been analyzed
    STEP 18A thru 18E item               STEP 18A thru 18E item                       STEP 18A thru 18F item                  STEP 18A thru 18F item
                                                    +                                            +
                                          No action taken costs                        No action taken costs
                                                                                                                                                                           Is hardware in-service or undergoing design testing?



          STEP 20                               STEP 20                                      STEP 20                                 STEP 20
                                                                                                                                                                         Design Testing                                In-service

       Analysis / Select                       Analysis/ Select                             Analysis/ Select                        Analysis/ Select
which option or combination of         which option or combination of               which option or combination of          which option or combination of
options is best at meeting RCM         options is best at meeting RCM               options is best at meeting RCM          options is best at meeting RCM                 STEP 24                                     STEP 24
            metrics                                metrics                                      metrics                                 metrics
                                                                                                                                                                    Review RCM results with                     Review RCM results with
                                                                                                                                                                     designers and potential                    SSWG, FST, maintainers
                                                                                                                                                                    operators/maintainers for                   and operators for inputs.
                                                                                                                                                                             inputs                                    (MODULE 14)
*
PM Task/s       Redesigned             Redesigned                       No action
                                                                                                       *
                                                                                                       PM Task/s
                                                                                                                             *
                                                                                                                            PM Task/s        Redesigned
 required        required               required                        required                        required             required         required
                                                                                                                                                                                             Recommended PM
                                                                                                                                                                                                acceptable?
                                                                        STEP 21
                                                                                                                                                                                              YES                 NO
                              GO TO                                                                                                             GO TO
                             STEP 2B                                    Provide                                                                STEP 2B
                                                     usage prediction data (STEP 13) to logistics to                                                                        STEP 25
                                                    ensure adequate replacement parts are available
                                                                                                                                                                                                                              Go to
                                                                                                                                                                            Perform                                          STEP 2B
                                                          No additional analysis is required.                                                                           Packaging Process
                                                                   GO TO STEP 23


                                                                                                                                                                            STEP 26
                                                                                                                                             STEP 22
                                                                              Was engineering judgment / estimated values
                                                                               used during any part of the RCM analysis?                                            Perform LORA and update
                                                                                                                                              Develop
                                                                                                                              YES        Age Exploration task
                                                                                                                                                                        maintenance plan

        *-                 PMA / APML
                                                                                                NO

                  Direct PM task to be implemented                                                                                                                               F
                      regardless of RCM results
FULL RCM PROGRAM TASK SEQUENCE FLOWCHART


                                                      F


                                                 STEP 27


                                                 Implement
                                                  PM tasks




                                                 STEP 28


                                                   Collect
                                           test and in-service data




                                                 STEP 29

                                          Does new data support
                                         current FMECA and RCM
                                                  entries?

                                           YES                 NO




                                     Go to                             Go to
                                    STEP 28                           STEP 6

								
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