Welcome to the ‘HIGH SCHOOL’ for RAM / LCC experts

Reading sample RAM / LCC

Andreas Kroenert Mobil (D): +49 1520 1683 928

on behalf of International Competence Centre Rail GmbH

Mitteldorfstrasse 17
CH – 6315 Oberaegeri
Switzerland

[email protected]
www.cc-rail.com
Itellectual properties

This document and its contents are the property of INTERNATIONAL COMPETENCE
CERTRE RAIL GmbH or its subsidiaries. This document contains confidential
proprietary information. The reproduction, distribution, utilization or the
communication of this document or any part thereof, without express
authorization is strictly prohibited. Offenders will be held liable for the payment of
damages.
© 2018 INTERNATIONAL COMPETENCE CERTRE RAIL GmbH or its subsidiaries. All
rights reserved

本文件及其内容属于国际铁路能力中心有限公司（CC-Rail）或其子公司。本
文件包含机密的专有信息。严禁未经明示授权的复制、分发、使用或传递本
文件或其任何部分。违者将承担赔偿责任。
© 2018 INTERNATIONAL COMPETENCE CERTRE RAIL GmbH or its subsidiaries. All
rights reserved

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only
Contents of the Course

A brief overview …
▪ Day 1 : Module 1 – Introduction to RAM
▪ Requirements within standards and regulations
▪ Normative requirements: IRIS, IEC 62278, EN 50126-1, TR 50126-3
▪ RAM life cycle phases and RAM tasks at tender, design and demonstration phases
▪ Day 2 : Module 2 – Reliability, Availability, RAM Demonstration and FRACAS
▪ Basic calculation methods, Reliability function, Availability up and down states
▪ Failure Mode and Effects Analysis (FMEA)
▪ Failure Reporting and Corrective Action System (FRACAS)
▪ Day 3 : Module 3 – Maintainability, Maintenance and Life Cycle Cost
▪ Maintainability as a design objective
▪ Preventive and Corrective Maintenance Analysis, LCC calculation
▪ Day 4 – Summary, tips and tricks, RAM and Integrated Logistic Support, final test
▪ Tips and tricks for RAM analyses and quotations
▪ Written examination and end of the training
Introduction

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 3
RAMS/LCC – Definitions and Measures

A brief introduction to the topic ...

Reliability Availability Maintainability Safety LCC Life Cycle Cost

Definition: Definition: Definition: Definition: Definition:
Ability to perform as Ability to be in a Ability to be retained Safety is the state of Cost of ownership
required for a given state to perform as in, or restored to a being protected
time interval under and when required, state in which it can against failure,
given conditions under given perform as required, damage, error,
conditions, assuming under given accidents, which
that the necessary conditions of use could be considered
external resources and maintenance non-desirable
are provided

Measure: Measure: Measure: Measure: Measure:

E.g. Mean Distance E.g. number of up E.g. Mean Time To E.g. Safety Integrity E.g. maintenance
Between Failures time hours Repair (MTTR), man- Level (SIL), Tolerable cost, energy
(MDBF) according to compared to total hours, tools Hazard Rate (THR) consumption
a specified failure hours or number of calculated and
category (e.g. delay) trains of a fleet validated according
available in the to an agreed model
morning

Module 1 – Introduction to RAM

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 4
IRIS Requirements

Requirements with a view to RAM Management

▪ Maintainability of the product shall be an integrated part of the design and
development Process
▪ Standardized routines for the Maintenance of software shall be established and
recorded according to IEC 62278 (EN 50126), IEC 62279 (EN 50128), IEC 62425
(EN 50129) or other agreed equivalent models in accordance with the design and
development Process
▪ The organization shall have a documented Procedure in place to cover all the
aspects of RAMS activities, including:
▪ Calculation and documentation
▪ Data collection, analysis and improvement action plan set up
▪ Implementation of defined tasks of the action plan
▪ Implementation of defined tasks of the action plan

Module 1 – IRIS standard

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 5
System RAM Life Cycle

RAM programme and life cycle phases EN 50126 and TR 50126-3

1 Concept
System definition and application conditions Risk
Tender 2
analysis
Phase 3 Risk analysis Preliminary
Analysis (1,2,4,5)
4 System requirements
5 Apportionment of system requirements
6 Design and implementation
Design 7 Manufacture
Phase 8 Installation
9 System validation
Demonstration
10 System acceptance
Phase (9,10,11)
11 Operation and maintenance
Operation 12 Performance monitoring
Phase 13 Modification and retrofit
14 Decommissioning and disposal
Module 1 – Implementation of RAM / Life cycle phases

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 6
Reliability

Survival function with the example of human beings

R(t) 100%

80%
(Probability of survival)

60%
Reliability

40%

20%

0%
0 20 40 60 80 100
Age of death (‘failure‘)

The probability of survival for a 60-years old man is 80%

80% of men will reach an age of 60 years or more, this is a probability of failure of 20%
Module 2 – Reliability / Survival function

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 7
Failures

Bathtub curve – schematic diagram

I II III

Failure rate
Decreasing Constant Increasing
failure rate failure rate failure rate

Observed
failure rate

Early failures
(‘infant mortality’) Wear out
failures

Random
failures

Time
Module 2 – Reliability / Failures

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 8
Reliability Performance Indicators

Reliability parameters – examples for repairable items

Symbol Parameter Dimension

MTBF Mean Time Between Failure Time
MDBF Mean Distance Between Failure Distance
MCBF Mean Cycles Distance Between Failure Cycle
MTBSF Mean Time Between Service (Affecting) Time
Failure
MDBSF Mean Distance Between Service Distance
(Affecting) Failure

Module 2 – Reliability / Reliability performance indicators

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 9
Failure Modes and Effects Analysis

Versions of the FMEA

FMEA

Component FMEA

Functional FMEA
Design FMEA Process FMEA
(System FMEA)

▪ Identification of weak points ▪ Identification of weak points ▪ Identification of weak points

in the system layout and in the system (component) in the manufacturing process
configuration design (also operation and
▪ Analysis of the effect of ▪ Analysis of the potential maintenance)
functional failures failure modes of system ▪ Process failures (human
▪ Derivation of improvement components errors, machines, methods,
measures within the system ▪ Strengthening of component etc.) are analyse with regard
architecture design (e.g. environmental to their impact of the system
▪ Aim: Improve reliability resistance) and/or components
▪ Aim: Improve reliability (quality)
Module 2 – Reliability /FMEA

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 10
Availability

Availability calculation using up and down states of a system

▪ Ratio of (Up’s) the operational time of an item and the total (possible) time

‘Down’ = 1 hrs ‘Down’ = 1 hrs ‘Down’ = 2 hrs

Total time T = 30 hrs

▪ Availability A =  Up’s =  Up’s = 26 h = 0,87 = 87%

T  Up’s +  Down’s 30 h

▪ Availability A [%] = Total time – Down time X 100

Total time

▪ Or: Availability A = MTBF X 100 with MDT = Mean Down Time

MTBF + MDT
Module 2 – Availability / Up and down states

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 11
FRACAS

FRACAS – Failure Reporting, Analysis and Corrective Action System

▪ Systematic approach to gather and analyse field data with the aim of identifying
weak areas and introducing corrective measures for improvement
▪ Key features: FRACAS closed loop and Failure Review Board (FRB)

Control improvement Reporting

- Verify corrective action - Failure reporting and monitoring
- Close-out Report - Key performance indicator, KPI:
MTBF, MDBF, MTTR, …

Corrective action Analyse

Resolution and - target actual-comparison, Pareto-Diagram
Control group implementation - root cause analysis

Module 2 – FRACAS / Definition

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 12
Weak Point Analysis

Identification of weaknesses and derivation of corrective actions

120 120

100 100 Failure mode 1

Corrective action 1
FPMK (km)

FPMK (km)
80 80
Failure mode 2
60 60 Corrective action 2

40 40
Target Target
Failure mode 3
Corrective action 3
20 20

0 0

Time Time
(month) (month)

Module 2 – Reliability Growth / Weak point analysis

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 13
Maintainability Targets

Catalogue of basic requirements see VDI 2246 Part 2

▪ Ability to identify
▪ Accessibility
▪ Interchangeability
▪ Serviceability
▪ Inspection
▪ Testing
▪ Transportation
▪ Storage http://www.pixabay.com

▪ Standardisation

Module 3 – Maintainability / Maintainability targets

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 14
Maintenance Types

Maintenance types according to EN 13306

‘Maintenance – Maintenance terminology’

Maintenance

Preventive Corrective
Maintenance Maintenance

Conditioned
Predetermined
Based
Maintenance
Maintenance

Scheduled,
on request, or Scheduled Deferred Immediate
continuous

Module 3 – Maintenance / Maintenance types

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 15
Maintenance Types

Potential-to-functional failure interval for Conditioned Based Maintenance

Condition

Worsening: Point where the failure starts to occur

Potential failure symptom:

Point where it can find out that an item is failing
P
Prerequisite:
P-F interval needs to be
long enough !

P-F interval
Lead time between the ability
to detect a failure process
and the actual loss of function
F Failure

Time (cycles, Mileage)

Module 3 – Maintenance / Maintenance types

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 16
Maintenance Strategy

Aspects for determining the maintenance strategy

▪ Safety and Availability
▪ Operation
▪ Environment
▪ Design (difficulty, complexity)
▪ Resources Maintenance
• preventive level • user
▪ Maintenance staff • corrective • line • manufacturer
▪ Qualification • condition based maintenance • third party
• shop
▪ Workshop facilities Maintenance maintenance
Maintenance
▪ equipment type provider

▪ Economic criteria and costs

▪ Laws, regulations, ordinances
▪ …

Module 3 – Maintenance / Maintenance strategy

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 17
Life Cycle Cost

LCC cost elements – example for railway applications (rolling stock)

Life cycle cost

Acquisition cost Operation cost Maintenance cost Disposal cost

▪ Vehicles ▪ Driver and/or train ▪ Preventive maintenance ▪ Disposal

▪ Initial spare part stock attended ▪ Inspection ▪ Replaced spare parts
▪ Warehousing ▪ Service ▪ Operating materials
▪ Strategic (main) spare
▪ Overhaul ▪ Recycling
parts ▪ Logistic, transport
▪ Corrective maintenance ▪ …
▪ Workshop and ▪ Periodic training
▪ Failures
equipment ▪ Energy consumption ▪ Vandalism
▪ Special tools ▪ Cleaning ▪ Accidents
▪ (Initial) Training (external/internal) ▪ Maintenance of spares
▪ … ▪ Management and ▪ …
administration
▪ …
Module 3 – Life Cycle Cost / Cost elements

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 18
Wrap-up

Summary – RAM activities along the V-cycle

FTA / RBD Overall System

Operation
reliability analysis
profile FAIL_ID

Failure effect and

System / Subsystem Maintenance task analysis
maintenance task RAM Demonstration
description (planning and support)
identification

(Technical) FMEA PM/CM-Analysis

Field data
Breakdown of parts LRU/LLRU_ID LRU/LLRU_ID
FRACAS
LRU/LLRU_ID FAIL_ID FAIL_ID

RCM / Field Experience /

subcontractor recommendations
standard and authorities regulations

Module 4 – Wrap-up

Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only 19
Contact

Your contact at CC-Rail

Andreas Heinzmann International Competence Centre Rail GmbH
CH – 6315 Oberaegeri
Switzerland
www.cc-rail.com

[email protected]

Mobil (D): +49 172 622 32 73

Phone (D):+49 333 977 33 37

I would be very happy to hear from you again.

If you leave me a message, I will aim to return
within 24 hours.

Module 4 – Contact

20