Reliability Analysis Center

IIT Research Institute Reliability Centered Maintenance

1 - 888 - RAC - USER

http://rac.iitri.org

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Description: eliability-centered maintenance (RCM) is without increasing the risk of failure. Based on
a systematic, decision-logic approach the results of this process, optimized mainte-
that analyzes failure modes, rates and nance task schedules can be defined to address
criticality data to establish a cost-effective strate- (1) inspection or measurement for parts more
gy in which scheduled replacement, preventive susceptible to failure, (2) rework or rebuild to
maintenance based on condition, periodic "like-new" condition, (3) removal/replacement
rework (overhaul), and scheduled inspections are with new parts/assemblies, or (4) inspection for
combined to minimize the cost of maintenance undetected failures.

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How It Can areful planning of a preventive mainte- RCM can determine which components can
B e n e f i t Yo u : nance strategy can greatly reduce the be restored to a "like-new" condition through
customer's cost of ownership. An effec- periodic rework in lieu of replacement. This
tive RCM program results in maintenance that is approach can be made more cost-effective by
event-based (miles driven, operating hours, etc.), designing the component for ease of rework.
rather than time-based. Development of such a Some components must be replaced as they
program depends on a determination of how a wear beyond safe limits. RCM analysis will iden-
product/system can fail, the consequences of tify them, determine their replacement intervals
failure, and the classification of failure distribu- and combine periodic maintenance tasks into
tions (infant mortality, random failures, or scheduled blocks. The results permit calculation
wearout). of spare parts requirements, economic schedul-
Preventive maintenance is typically per- ing of maintenance and best use of available
formed to preclude wearout failure modes, such manpower.
as those experienced in airplanes or automobiles. Redundant or back-up components are
As such, it can be quite expensive. RCM is often used to ensure that a failure does not have
designed to minimize costs without increasing serious consequences. These components, how-
the probability of failure through a logical analy- ever, can also fail. If the failure is not obvious,
sis of preventive maintenance needs and can be protection may be removed without the cus-
used as both a design and logistics tool. tomer's knowledge. RCM analysis includes
One of the basic principles of RCM is that detectability of failures, and provides for period-
the most economical replacement strategy is ic inspection of "hidden" components.
based on the condition of the components. For An effective RCM program includes the
example, tires are replaced when a visual inspec- analysis of maintenance data to refine the strate-
tion indicates the tread is worn beyond accept- gy for higher cost savings. Unnecessarily short
able limits. An RCM analysis during maintenance intervals can be corrected, and
product/system design can highlight opportuni- unforeseen failures can be analyzed and incorpo-
ties to add condition-monitoring capability to rated into updated maintenance plans.
components.

RAC is a DoD Information Analysis Center sponsored by the Defense Technical Information Center and operated by IIT Research Institute
Reliability Centered Maintenance

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R A C C a pa b i l i t y : AC has extensive experience and exper- databases of failure rate, failure mode, and ESD
tise in all aspects of reliability-centered susceptibility data over the last 30 years.
maintenance. This capability includes RAC engineers are also skilled in applying
(1) analytical techniques and field experience data the decision logic on which RCM analysis is
collection, which are both critical elements of based. In addition to the practical application of
RCM, and (2) the integration of these elements these skills for numerous customers, RAC offers
into an effective RCM program. the capability to provide RCM training, either in
An integral part of RCM is the use of fail- customized courses, or as a segment of its
ure modes, effects and criticality analysis Mechanical Reliability course. RAC expertise has
(FMECA). FMECA results help determine the also been solicited by the government to create a
feasibility of various maintenance strategies and RCM military standard for use by all DoD com-
the consequences of component failure. RAC ponents.
engineers have demonstrated expertise in numer- RAC has conducted successful RCM pro-
ous FMECA applications, and provide training in grams for a number of customers, including the
these techniques as part of RAC-developed US Air Force and Marine Corps. The latter pro-
courses in Design Reliability and Mechanical ject resulted in over 100 changes to improve the
Reliability. RAC was also selected by the US established preventive maintenance strategy for
Naval Air Engineering Center to author a Navy tactical vehicles. It also established the
handbook on FMECA. Reliability-Centered Maintenance Data Analysis
The initial maintenance strategy derived Center for the Marine Corp. In another effort,
through RCM analysis is refined by age explo- RAC experts and computer engineers developed
ration to determine the adequacy of the strategy a networked, automated tool for RCM analysis.
in the field, over time. Effective analysis of field This tool permitted a team of analysts to effi-
data will show whether maintenance intervals ciently work together to perform all of the RCM-
may be safely lengthened, and when preventive related tasks, including FMECA, the application
maintenance actions are necessary. RAC is of RCM decision logic, the use of field data in
uniquely qualified in the collection and analysis age exploration, and the management of the pre-
of operational data, having established extensive ventive maintenance schedule.

C o n ta c t : Reliability Analysis Center (RAC)

We b s i t e : http://rac.iitri.org

Reliability Analysis Center