RELIABILITY

CENTERED
MAINTENANCE
(RCM)
By Arif Abdul Rohman
 Evolution of Maintenance
First Generation 2nd Generation 3rd Generation
Fix it when broke Scheduled replacement Condition Monitoring
Corrective Maintenance Planning and controlling work Design for Reliability &
(+) Maintainability
Higher Plant Availability Hazard Studies
Longer Equipment Life Small, Fast Computers
Lower Cost FMEA
Preventive Maintenance / Time – Expert System
194 Based Maintenance Multitasking and Teamwork
0-1 (+)
9 50 Higher Plant Availability & Reliability
Greater Safety
196 Better Product Quality
0-1 Environment Friendly
9 70 Longer Equipment Life
Greater Cost Effectiveness
198 Predictive Maintenance
0-2
0 00
 Evolution of Maintenance
● Some failure show that not only one maintenance strategy

suitable to use. For example, maintenance of engine is

treated differently with lamp.

● So, it is a need balance of maintenance strategy

● Reliability Centered Maintenance is approach to balance

those maintenance strategy; Corrective, Preventive, and

Predictive

● This approach firstly applied by Aviation Industry

Reliability & Availability
 Availability & Reliability

Reliability is the level that shows equipment

are able to deliver its function without Failure,

during a certain time, and certain condition

Availability is level that shows readiness of

equipment to be used / utilized

 Availability
𝑴𝑻𝑩𝑭
𝑨𝒗𝒂𝒊𝒍𝒂𝒃𝒊𝒍𝒊𝒕𝒚 =
𝑴𝑻𝑩𝑭 + 𝑴𝑻𝑻𝑹

MTBF [Mean Time Between Failure] : the

average time the machine operates before it fails

MTTR [Mean Time to Repair] : average time

needed to do repairation
Translating Availability
 Improving Availability
1. detailed work plan

2. clean equipment during maintenance

3. equipment data completeness

4. Quality checklist (checksheet & WI)

5. Material readiness

6. competence of workers
 Reliability (R)
−𝝀𝒕
𝑹 ( 𝒕 )=𝒆 ● Reliability always change based on function of time. So, talking

about reliability of equipment must followed by span of time

considered
𝑅 ( 𝑡 )=1 − 𝑃 ( 𝑡 )
● P(t) is probability of failure symbol within a certain time span(t)

● Failure rate is number of failure within certain time analyzed

● e is Euler Number : 2,71828

Failure Rate
● Reliability of equipment will influence system reliability, please
1
( )
𝜆 𝑡=
𝑀𝑇𝐵𝐹 learn more about reliability of Series system, Parallel System/

Redundance to more understand about Reliability !!!

 Reliability Curve
1
● The curve show level of failure rate by time

2
● For 1 &2 we can apply useful age limit

3 ● (3) It’s difficult to apply useful age limit ; aircraft turbine

● (4&5) impossible to apply useful age limit

4

● (6) It’s difficult to apply useful age limit ; Electrical equipment

5
RCM IMPLEMENTATION &
TEMPLATE
 RCM Implementation Flowchart
Fa ilu r e

Fa ilure influe nc e He a lth, No Fa ilure influe nc e Vis ion, No Fa ilure c a us e Big No

S a fe ty, Environm e nt? Mis s ion, Com p a ny Va lue ? Ec onom ic a l Los s e s ?

Yes Yes Yes

Yes Is The re Fa ilure

De te c tion Te c hnolog y ?

Install Technology No

Fa ilure ha s Fa ilure P a tte rn?

No
(Tim e Inte rva l)

Yes

Re-design System
Use Redundance
Predictive Maintenance Predictive Maintenance Run To Fail
Jaccept the risk of failure
 RCM Basic Template
Influence Vision, Cause Big Suitable
System / Equipment / Component Detection Replacement
No. Tag Number Part Number SC / SKU Price (USD) QTY Influence HSE? Mission, Core Value Economical Failure Pattern? Maintenance
/ Part Technology? Frequency
of Company? Losses? Strategy

Only Basic information of System / To fill this cell, if we want to get Logic function based
Equipment / Component quality result a lot of tools can be on RCM flowchart, if
used such as RCA, FMEA, etc. we used excel just use
IF OR AND Function
 THANKS
Please advice for Improvement
[email protected]
+62 81 XXXXXX

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