Aziz Lachemot Implementing RCM to an Operating Railway
John Holland
IMPLEMENTING RELIABILITY CENTRED MAINTENANCE (RCM)
TO AN OPERATING RAILWAY
Aziz Lachemot
Master Degree in Reliability and ILS Engineering
Engineering Degree in Production and Mechanical Engineering
Engineering Degree in Electronic Engineering
John Holland Rail Pty Ltd
SUMMARY
Reliability Centred Maintenance (RCM) is a closed-loop continuous improvement method for
determining and updating maintenance requirements based on the analysis of the likely functional
failures of systems/equipment having a significant impact on safety, operations, and lifecycle cost.
In its simplest form, by highlighting the failure modes with high probability and severity of
consequences, RCM will direct a maintenance regime (including operation procedures) where it will
produce the greatest value.
In December 2010, John Holland Rail Pty Ltd was contracted through an Operations and
Maintenance Deed (O&M Deed) by Country Rail Infrastructure Authority (CRIA) (now Country Rail
Contracts of Transport for NSW) to manage, operate, maintain and upgrade the CRIA Assets, and
carry out other associated and ancillary obligations as set out in the terms of the Deed. The O&M
Deed was for an initial period of 10 years.
When John Holland Rail Pty Ltd was accredited as Railway Infrastructure Manager (RIM) to operate
and maintain the Country Regional Network (CRN), the legacy included an established operation and
maintenance regime from the previous RIM.
John Holland Rail Pty Ltd challenged the previous maintenance regime by implementing the RCM
method. To do so, operation and maintenance team members have been trained in order to perform
the required analysis, reports, and updates to successfully roll out the RCM process to date.
1 INTRODUCTION 2 NOTATION
Under an Asset Management strategy, RCM is AO: Operational Availability
an improvement process using reliability CM: Corrective Maintenance,
engineering techniques with benefits on asset CRN: Country Regional Network,
performance, maintenance and lifecycle cost. DOD: Department of Defence,
EN: European Norm,
On an operating railway, the successful roll out FMECA: Failure Mode Effect and
of RCM depends on the people responsible for Criticality Analysis,
its implementation. This involves the leaders FRACAS: Failure Reporting Analysis and
and team members responsible for Corrective Action System,
implementation, having the appropriate LCC: Life Cycle Cost,
training in order to understand clearly the RCM MTBF: Mean Time Between Failures,
process and its tools. MDT: Mean Down Time
MIL-HDBK: Military Handbook,
Therefore, specific training has been MIL-STD: Military Standard,
developed in accordance with the four main MTTR: Mean Time To Repair
phases of the closed-loop RCM process. PM: Preventive Maintenance,
RAM(S): Reliability, Availability,
Maintainability and Safety,
AusRAIL PLUS 2013
26 – 28 November 2013, Sydney
Aziz Lachemot Implementing RCM to an Operating Railway
John Holland
RCM: Reliability Centred Maintenance,
RIM: Rail Infrastructure Manager
3 RELIABILITY CENTRED MAINTENANCE
3.1 History of RCM
Reliability Centred Maintenance (RCM) is a
technique initially developed by United Airlines
in the 1960s when wide-body jets were being
introduced into service. Because of the
increased size and complexity of these aircraft,
airlines were concerned that the continuing
use of traditional maintenance methods would
make the new aircraft uneconomical.
Previously, preventive maintenance was
primarily time-based. In contrast, RCM is
condition-based, with maintenance intervals Figure 1: Closed-loop RCM Process
based on actual equipment criticality and
performance data. Technically, RCM is based on the analysis of
the likely functional failures of
After adopting this approach, airlines found systems/equipment having a significant impact
that maintenance costs remained about on safety, operations, and lifecycle cost.
constant, but that the availability and reliability
of their aircraft improved because effort was By highlighting the failure modes with high
spent on maintenance of equipment most probability and severity of consequences,
likely to cause serious problems. As a result, RCM directs the maintenance regime
RCM is now used by many of the world's (including operation procedures) where it will
airlines. produce the greatest value for an optimised
cost.
In the late 1970s, the United States
Department of Defence (DOD) released the The core of RCM sits in the ‘Analysis’ and
seminal book entitled Reliability-Centred ‘Sustain’ phase (refer to Figure 1) which is
Maintenance (RCM) [1]. based on the analytical techniques used in
Reliability Engineering: Failure Mode Effect
3.2 RCM Process and Criticality Analysis (FMECA, refer to 3.3.1)
and stochastic analysis (refer to 3.3.2 for
Following the United State DOD publication, definition).
RCM is now applied to engineering projects as
a closed-loop continuous improvement method 3.3 RCM Tools
(refer to Figure 1) for determining and updating
maintenance requirements. 3.3.1 FMECA
Each of 4 main RCM phases (‘Planning and The RCM analysis process centres on the
Preparation’, ‘Analysis’, ‘Implementation of assets functions, failure modes, failure
Results’ and ‘Sustain’) respectively refer to consequences and measures of mitigation to
classic engineering project phases ‘Concept’, prevent or cope with functional failure.
‘Design’, ‘Operation & Maintenance’ and Therefore, the questions asked to set up the
‘Performance Monitoring’ (as described in RCM process are:
railway standard EN 50126 [7]). What are the functions and performance
standards?
In what ways can it or does it fail to fulfil its
functions?
What causes each functional failure?
What happens when each failure occurs?
In what way does each failure matter?
What can be done to predict or prevent
each failure?
AusRAIL PLUS 2013
26 – 28 November 2013, Sydney
Aziz Lachemot Implementing RCM to an Operating Railway
John Holland
What should be done if a suitable proactive
task cannot be found? To reach this stage, JHR first implemented its
chosen Asset Management Model which is
The FMECA is the process which provides based on the Asset Management Council
effective answers to the questions above. Asset Capability Delivery Model. Within the
These answers will outline the preventive framework thus established, the necessary
maintenance strategy. work to progress through the Planning and
Preparation, Analysis and Implementation of
3.3.2 Stochastic Process and Analysis Results has been done to arrive at the present
state.
In probability theory, stochastic process is the
collection of random variable depending on
variable parameter. For instance, stochastic
analysis is used in meteorology to gather
temperature data over time and seasons to do
weather forecast.
Applied to Reliability Engineering, the
stochastic process defines the random
variable as an asset failure and the variable
parameter as the time. Therefore, a stochastic
analysis is the monitoring of an asset reliability
performance over a defined period of time.
Technically, the stochastic process sits within
the FRACAS which is the RAM tool used to
report, identify and analyse failures in order to
monitor asset reliability performance against a
maintenance strategy.
Figure 2: Detailed RCM Process
4 CASE STUDY: COUNTRY REGIONAL The RCM process involves all roles within the
NETWORK (CRN) business, and its successful implementation
relies on a top down approach: from managers
John Holland Rail Pty Ltd (JHR) is the providing the scope of work and the targets to
accredited RIM for the NSW CRN. JHR be met, to engineers providing analysis and
commenced operations on the CRN in January reliability performance of the system, to
2012 with inheritance of the maintenance technicians ensuring on-field data are
regime and operation procedures from the collected.
previous RIM.
Training is a compulsory step to ensure that
The goal of applying the RCM process to CRN the people involved in the deployment of RCM
is to update the maintenance regime and have the best understanding of the method
operational procedures in accordance with the and fulfil their role and to optimise the benefits.
current asset reliability performance.
4.1 RCM Implementation 4.1.1 Planning and Preparation
Figure 2 depicts the activities and During the Planning and Preparation phase, a
documentation involved in the implementation RCM plan is prepared to define process
of the Closed-loop RCM Process detailed in structure, roles and responsibilities to be
Figure 1. The JHR CRN Project is evaluated fulfilled (refer to Figure 3).
as currently being in the ‘Sustain” phase,
specifically focussing on Performance As part of the comprehensive JHR Learning
Monitoring. In demonstration of this, a and Development Plan, a specific training in
comprehensive FRACAS, using Maximo [8], RCM was provided to staff included as follows:
has been established. This permits close Introduction to RCM process course for
monitoring of the reliability performance of the managers and engineers,
operational assets. FMECA course for engineers,
AusRAIL PLUS 2013
26 – 28 November 2013, Sydney
Aziz Lachemot Implementing RCM to an Operating Railway
John Holland
Failure Reporting, Analysis and Corrective 4.1.2 Analysis
Action System (FRACAS) course:
One of the first steps of analysis requires the
o For engineers, the course presents
gathering of maintenance and reliability data
FRACAS data analysis and FRACAS
for the candidate items (refer to Figure 4) Data
reporting.
may also include hardware partitioning and
o For technicians, the course presents the
functional analysis to understand the system
importance of on-field data and its
design.
management within FRACAS.
Managers ensure the relevant people in the
organisation are involved in the training and
cross functional working relationship is
established.
Engineers perform the analysis using RCM
tools with inputs from maintenance Figure 4: RCM – Analysis Phase
technicians.
At design stage, these data sets would have to
Maintenance technicians ensure quality, be defined to structure the maintenance
availability and usefulness of on-field data strategy and support system around the
(=inputs) are provided when required. system to be designed.
For an operating system, these data sets are
available. The maintenance data has been
inherited from the previous RIM and asset
owner, and the reliability data is to be worked
out from the in-field data (FRACAS).
Figure 3: RCM - Planning and Preparation
Phase All these data sets are necessary inputs to
perform the FMECA [4] which the core of RCM
The RCM plan will provide the selection Process (as defined under [1]).
criteria for candidate items to go under
analysis. For each candidate item, FMECA is performed
in 2 main stages (refer to Figure 5):
The selection criteria are mostly maintenance Failure identification which defines for the
based and related to the preventive candidate items the failure modes, causes
maintenance parameters such as the and consequences; and,
frequency, criticality and/or cost being the Failure management which categorises the
main criteria for this case study. Additional failure modes by likelihood, criticality and
criteria may also be included to the selection of severity on operation, safety and cost.
candidate items. Failure mitigation is also part of failure
management.
For this case study, several signalling assets
have been selected as candidate item. These Within CRN, the means of mitigations are
candidate items have Technical Maintenance already represented by the preventive
Plans (TMPs) with high frequency which maintenance actions which are selected
increases maintenance labour cost and against the candidate items failure modes,
potentially consumables and spare parts cost such as the frequent lubrication of a ground
depending on the nature of the TMP. frame bearing to prevent wearing.
The preventive maintenance actions are the
Finally, the RCM plan outlines: CRN Technical Maintenance Plans (TMPs).
The review process to be established for
the overall RCM documentation and,
The ground rules and assumption which
define the reliability engineering
background for the systems under analysis.
AusRAIL PLUS 2013
26 – 28 November 2013, Sydney
Aziz Lachemot Implementing RCM to an Operating Railway
John Holland
Figure 7: RCM – Sustain Phase
In case of outstanding issues or hardware
changes, new candidate items may be
considered to go through the RCM process.
The stochastic analysis allows updating the
reliability trend for the candidate items based
Figure 5: FMECA Process on new in-field data to ensure the assumptions
for the RCM are still appropriate.
The FMECA is an important exercise which
provides the necessary engineering The FRACAS report is then reviewed to
background in order to review and update the present the latest reliability trend analysis
preventive maintenance regime. (refer to Figure 7) and also includes additional
RAM values and cost drivers such as Mean
The FMECA outputs are documented in the Time Between Failure (MTBF), Mean Time To
FMECA report and also outline the Repair (MTTR), Mean Down Time (MDT),
Maintenance Plan which presents the updates labour and spare part cost.
to be implemented in the maintenance
programme. The RCM loop is then closed. The updated
reliability performance, outputs of the
4.1.3 Implementation of Results stochastic analysis, will become inputs to the
FMECA which articulates the maintenance
At the Implementation stage, the updated strategy around the system reliability
preventive maintenance tasks (TMP and performance.
scheduled services) are re-packaged by
frequency, asset type and location. The The benefit of RCM will be realised over time
packaging goal is to optimise time along with through this process of formal monitoring and
cost. continuous improvement.
Then all updated maintenance tasks are 4.2 RCM Benefits
transferred in the overall maintenance
programme (refer to Figure 6). RCM benefits impact maintenance, operation
and lifecycle cost. The expected advantages
for the Owner are:
On performance:
o longer intervals between condition
Figure 6: RCM - Implementation of Results monitoring and overhauls,
Phase o shorter work lists, leading to shorter,
more easily managed and less costly
As the CRN maintenance programme is set up shutdowns,
within Maximo [8], the updates can be directly o the elimination of unreliable
loaded into it, providing an interactive components,
maintenance data base. o quicker diagnosis of failure,
On cost:
4.1.4 Sustain o less unnecessary routine maintenance,
o prevention or elimination of expensive
Once the updated maintenance programme is failures,
rolled out on the railway network, the o less need to use expensive experts
candidate items are closely monitored. because everyone has a much better
knowledge of the asset and process,
AusRAIL PLUS 2013
26 – 28 November 2013, Sydney
Aziz Lachemot Implementing RCM to an Operating Railway
John Holland
The author would also like to convey thanks to
On maintenance support: the whole CRN Team, technicians, engineers
o reduces the impact of staff turnover with and managers, for their availability and for
its attendant loss of experience and providing all information required to perform a
expertise, successful case study.
o provides a better understanding of the
asset in its operating context,
7 REFERENCES
5 CONCLUSIONS [1]. United States of America Department of
Defence, Reliability Centred Maintenance
The successful implementation of RCM (RCM) Process, MIL-STD-3034, 2011.
process is heavily dependent on 3 key drivers: [2]. United States of America Department of
the training of the CRN team and, Defence, Reliability Centred Maintenance
the close-monitoring of the implemented for Naval Aircraft, Weapons System, MIL-
results of this case study STD-2173, 1986.
close support of the owner. [3]. International Atomic Energy Agency,
Application of Reliability Centred
The training of CRN managers, engineers and Maintenance to Optimize Operation and
technicians establishes the cross working Maintenance in Nuclear Power Plants,
relationships between the participants in the IAEA-TECDOC-1590, May 2007.
RCM implementation. The training also [4]. United States of America Department of
provides a better understanding of RAM Defence, Procedures for performing a
Engineering and its application to operating Failure Mode Effect and Criticality
assets which is part of an overall Asset Analysis, MIL-STD-1629A, 1980.
Management Strategy within JHR. [5]. United States of America Department Of
From a technical aspect, the close monitoring Defence, Failure Reporting Analysis and
of the implemented results is important to Corrective Action System, MIL-STD-2155,
ensure the continuity of the closed-loop 1985.
improvement process. [6]. ZWINGELSTEIN (G,), Optimisation de la
Maintenance par la Fiabilité, Maintenance
The next step for the CRN team is to extend et Entreprise N454, Septembre 1992.
this case study to the rest of the operating [7]. National Standard Authority of Ireland,
assets. Railway Application – The Specification
and Demonstration of Reliability,
Availability, Maintainability and Safety
6 ACKNOWLEDGMENTS (RAMS), EN 50126:2001, June 2011.
[8]. Maximo is a propriety product provided by
The author wishes to express his gratitude to IBM.
the CRN Asset & Engineering Services
Manager, Glenn Dewberry, who provided the
opportunity to undertake this study.
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26 – 28 November 2013, Sydney
