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Decoding Reliability-Centered Maintenance Process for Manufacturing Industries

Date: 24 Apr 2021 13:33:47

Thereare cases where breakdowns and failures are not the primary cause of equipmentdowntime, especially in manufacturing industries. Although RCM is a popular maintenancestrategy, many manufacturing industries are still not implementing this processand continue to remain stuck in their PM tasks activities. The main reason whyI wrote this book is that doing RCM in a manufacturing plant is a bit differentfrom doing RCM in oil and gas, power plants, and other similar plants becausetheir equipment losses are different. Althoughthe process on how RCM is done will be the same. If you worked in a semiconductorplant, breakdowns and failures are not the main issues on the machines, butminor stoppages, changeover, and quality problems are. You must know the boundary between what RCMcan address and what it cannot. RCM willaddress failures and breakdowns by proposing maintenance tasks; it is notdesigned to address every possible equipment loss. What I am saying is thatfailures are just a subset of the entire equipment losses. Suppose you havechronic quality problems caused by the equipment; RCM can address some of them,but not all, since Quality problems and defects are much broader than breakdownand failures. I have a detailed explanation of what particular losses RCM canand cannot address in Chapter 3.3.2 of this book. This book is written to helpand provide detailed guidelines for manufacturing industries on implementingRCM on their machines, equipment, and assets. Some of the highlights of thisbook include:

27 Frequently Asked Questions (FAQ) on RCM
22 Tips on Implementing RCM- 15 Don'ts About RCM
Why the RCM Preparatory Stage is Important
Detailed Guidelines in Doing the RCM Preparatory Step
Can RCM Address All Equipment Losses?
Actual Case Study on RCM: Air Handling Unit Case
Role of Operators in the RCM Analysis
How to Integrate RCM into the TPM Process
Bonus: RCM Forms I used in Excel Format
The RCM and TPM Crossroads - Do they have different or the same paths
Strengthening the SAE JA1011 Criteria
Addressing MRO Spare Parts after Implementing RCM
How to Determine the Correct Interval for PM, PdM, FFT, andSwitching Standby Components
MRO Decision Diagram on Whether to Stock or Not to Stock
Difference Between a Failure Mode and a Root Cause
Secondary Tasks for Doing On-Condition Tasks
Detailed Guidelines in Writing the RCM Decision WorksheetExplained
Detailed Guidelines in Writing the RCM Information WorksheetExplained
Detailed Guidelines in performing Horizontal Replication forSimilar Equipment with the Same Operating Context
Detailed Guidelines in Conducting the RCM Audit and many more . ..

In this book, I haveexplained two definitions of RCM, which is looking on the equipment side andthe human side of doing it. From anequipment point of view, Reliability-Centered Maintenance is a process used todetermine any physical asset's maintenance tasks, decisions, and requirementsin its current or present operating context. It is also a process used to determine whatmust be done to ensure that any physical assets continue to do whatever theirusers want them to do in their present operating context. On the other end,from a human point of view, RCM is a way or process of capturing and extractingthe knowledge, understanding, experience, and wisdom of the most experienced peoplein the plant and transforming it into a living document and their legacy. In most cases, when these good old folks goaway and retired for good, they bring everything they know to their grave. The plant hires fresh employees with littleor no experience and starts everything again from the very beginning. We justwant to put a stop to this never-ending cycle. I have also explained in thisbook how to implement RCM more successfully by restoring the equipment first.

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