The Reliability Centred Maintenance (RCM) process has been documented widely since its birth in the aviation industry. There are numerous case studies that have identified the great benefits of RCM; improving equipment performance and reliability while lowering maintenance costs and minimising production downtime.

Significant challenges needed to be overcome, to achieve an effective RCM process, are as follows;

  • Personnel are reluctant to take part due the significant time impact of the process.
  • A complex RCM may take weeks to complete;
    • the FMECA (Failure Mode, Effects, and Criticality Analysis),
    • define mitigating actions,
    • develop the preventative maintenance plans and,
    • schedule the maintenance in the CMMS.

Challenges

Developing the PM’s and implementing the strategy in the CMMS is the most time consuming aspect of completing an RCM.

Challenges commonly faced include;

  • Time consuming.
  • Developing work instruction is tedious.
  • Formatting of documents to meet corporate standards is inefficient when done manually.
  • Manipulating data to match CMMS import requirements can be difficult.
  • Understanding the CMMS characteristics is difficult and requires specialist knowledge.
  • Ensuring maintenance strategies meet CMMS corporate standards.
  • Compromised data quality.

An RCM workshop focussing on one piece of equipment can lead to the creation of hundreds of documents for technicians to perform maintenance, taking weeks and months to develop.

There has to be an easier way!

Solution

To overcome the challenges of implementing outcomes of an RCM workshop, ARMS Reliability has developed a proprietary software application (The Reliability Integration Tool), which interfaces with Isograph’s Availability Workbench software suite.

How the Reliability Integration Tool works

This application is able to access the contents of the RCM database, extract the required data and convert the information into compliant primary maintenance instructions (PM) and create load sheets for the CMMS system.

What are the benefits of using the tool

  • Primary maintenance instruction for a piece of equipment can be generated from the RCM database in minutes.
  • Removes the need for hiring a specialist document writer to ensure documents are formatted correctly to meet corporate standards.
  • The need for a CMMS specialist is not required, as the Reliability Integration Tool is able to produce load sheets for the CMMS in a matter of minutes, without expert knowledge of the system.
  • A process that was done by a handful of individuals within the organisation can now be done by any personnel with access to the tool.
  • Reduction in time spent reworking documents as they are fixed globally and recreated quickly.
  • By automating the process between the RCM database and the implementation stage, data is not compromised.
  • The tool can be customised to fit each company/site’s specific requirements and standards.

Success

In a recent RCM project performed for a major Australian Mining Company (using the Reliability Integration Tool), we were able to reduce the time to create and implement outcomes of the RCM workshop from months to weeks. Specialist resources such as a Document Writer and CMMS professional were not required. This project had over 120 pieces of equipment, meaning a project that would normally have taken two years was completed in less than six months.

Learn more about the integration tool and how it can assist you in implementing the outcomes of your RCM Workshops 

 

Amir Datoo
Reliability Engineer – USA


About adatoo

Amir Datoo is an experienced Reliability Engineer currently based in the USA. He has worked extensively with major international companies to integrate their data and CMMS systems

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