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Copyright 2008 Allied Reliability, Inc. All rights reserved. Any unauthorized use, sharing,
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whatsoever, without the express written consent of the publisher.

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Allied Reliability, Inc.
4360 Corporate Rd #110
Charleston, SC 29405

Phone 888-414-5760
Fax 843-414-5779

info@alliedreliability.com
www.alliedreliability.com


3rd Edition
January 25, 2008
WHY RCM DOESN’T WORK
                                         How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends



                          Table of Contents

                            RCM Made Simple…………………………………………………........                                                     3

                            Does RCM Work for Manufacturers?.................................................              6

                            RCM is too Resource Intensive
                                 Mistake #1…………………………………………………………                                                          7

                            RCM is Just too Complex
                                 Mistake #2…………………………………………………………                                                          8

                            Moving Forward Without A Plan
                                  Mistake #3…………………………………………………………                                                     12

                            RCM is All About Condition Monitoring
                                 Mistake #4………………………………………………………...                                                    15

                            We Expect More From The RCM Process Than We Do
                             From Our Leaders
                                 Mistake #5….……………………………………………………..                                                    16

                            About Allied Reliability…………………………………………………...                                             18




©2007 Allied Reliability, Inc                         Page 1 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK



                            Introduction
                            Reliability Centered Maintenance (RCM) is a proven, logical, sensible
                            approach that helps companies improve reliability.

                            Yet most companies are not getting the return they expected. They see
                            RCM as too much trouble for too little reward.

                            So that’s why we decided to publish this new report. Find out why
                            RCM doesn’t work, what needs to change and how to put RCM to work
                            at your company so it doesn’t become another Resource Consuming
                            Monster.




www.alliedreliability.com                         Page 2 of 18                  ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends



                           RCM Made Simple
                           It has been almost 30 years since Stanley Nowlan and Howard Heap
                           published quot;Reliability Centered Maintenancequot;, the ground-breaking
                           study that changed maintenance forever.

                           Yet myth, mystery and confusion about RCM still abound. So let's
                           begin with the basic truths.

                           To paraphrase RCM practitioner, Doug Plucknette, of Allied Reliability,
                           RCM is a structured process developed to ensure the designed safety
                           and reliability capabilities of a process or piece of equipment. The
                           beauty of understanding the RCM process is it can be applied to
                           virtually any physical asset in any plant around the world.

                           RCM's roots go back to the early 1960's, when the commercial airline
                           companies were considering buying the new jumbo jet, the Boeing
                           747.

                           At the time, the airlines religiously practiced time-based preventive
                           maintenance. Why? Because the conventional wisdom was that
                           equipment wears out over time. So that meant taking planes out of
                           service for maintenance every 1,000, 5,000 or 10,000 hours.

                           But the problem with the 747's was the amount of maintenance
                           specified by federal regulators was three times more than the
                           maintenance required for Boeing 707's. That meant more time in
                           maintenance, more time out of service, and a huge disruption to
                           operations.

                           Clearly, the airlines' traditional approach to maintenance would not be
                           economically feasible for the new jumbo jets.

                           So the airlines had two choices: Either buy a larger fleet of planes or
                           develop a more economical approach to maintenance.

                           That's why United Airlines led a task force to re-evaluate the concept of
                           preventive maintenance and determine the most economic strategy,
                           without compromising safety. The result was the process that we now
                           know as RCM, which was successfully employed on the 747 and all
                           subsequent jet aircraft.




©2007 Allied Reliability, Inc.                      Page 3 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK


                            Who Developed RCM?

                            United, along with and Boeing Aircraft Corporation, were the early
                            pioneers of RCM. Other airlines also considering buying the new 747's
                            joined the task force and contributed to the process.

                            But it was Boeing and United who took the lead in developing a logical,
                            rational approach to maintenance that would also be acceptable to the
                            federal regulators.

                            In 1976, the U.S. Department of Defense contracted with United to
                            publish how airlines develop maintenance programs. The result was
                            quot;Reliability Centered Maintenancequot;, a landmark 495-page report by
                            Stanley Nowlan and Howard Heap, which described the RCM
                            methodology developed for the Boeing 747, Douglas DC-10 and
                            Lockheed 1011.

                            (Nowlan was the Director of Maintenance Analysis for United; Heap
                            was United's Manager of Maintenance Program Planning.)

                            In 1978, the Defense Department placed the report in the public
                            domain for use by anyone interested in it.

                            How RCM Revolutionized Maintenance

                            The key to RCM was abandoning the philosophy of quot;preserve-
                            equipmentquot; in favor of quot;preserve-functionquot;. Simply put, equipment
                            became the means to an end, not the end in itself.

                            In addition, Nowlan and Heap concluded that a maintenance policy
                            based on operating age would have little, if any, impact on failure
                            rates. Thus, applying time-based maintenance on equipment which
                            has no quot;wear-outquot; pattern was futile. This forced a change in
                            philosophy from, quot;It wasn't broke, but we fixed it anywayquot; to quot;If it ain't
                            broke, don't fix itquot;.

                            Nowlan and Heap also concluded that:

                            - Time-based maintenance works only for a small percentage of
                              components, and then only when there is solid information on their
                              quot;wear-outquot; characteristics”.

                            - Condition Based Maintenance (CBM) is the most-preferred option.
                              That means monitoring, observing and taking non-intrusive actions,
                              such as lubricating and cleaning, until a condition signals that
                              corrective action is necessary.



www.alliedreliability.com                           Page 4 of 18                    ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           - Run-to-failure is a viable tactic in situations when there is no safety
                             and little economic impact.

                           - In a significant number of situations, the very act of maintenance itself
                             causes subsequent failure of the equipment.

                           - Non-intrusive maintenance tasks should be used instead of intrusive
                             maintenance whenever possible. In other words, don't do any
                             maintenance, except monitoring and non-intrusive sustaining actions,
                             until condition directs intrusive corrective action.

                           RCM Pitfalls

                           In the last 40 years, no better method than RCM has been found for
                           determining what maintenance should be performed. Four statistically
                           significant studies have confirmed the validity of RCM.

                           Yet, in a survey conducted by Reliabilityweb.com in 2005, several
                           companies offered the following excuses when it came to their failure
                           to begin or implement RCM as a reliability tool.

                           quot;Mining, like all industries, wants results right away, not in 6 months or
                           a year. The classical RCM process is too time and resource intense.quot;

                           quot;RCM is a great tool but very resource intensive.quot;

                           quot;100% reliability is extremely expensive, difficult to attain, and not
                           necessarily the right answer.quot;

                           quot;RCM is misunderstood to be software.quot;

                           quot;In the beginning, it was hard. And it is still a challenge to steer the
                           mind-set toward more condition-based maintenance than time-based.quot;

                           quot;We always ran into the problem with implementation. In the few
                           places where we implemented it successfully, it was at the
                           maintenance level. And recognition for it was non-existent.quot;

                           quot;The system is very strong but too high level ...quot;

                           The truth is, there are many pitfalls in RCM. But few get revealed
                           when an RCM project fails. You see, nobody wants to write an article
                           or present a paper at a conference which reveals how money was
                           wasted and great visions were never realized.




©2007 Allied Reliability, Inc.                       Page 5 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK



                            Does RCM Work for Manufacturers?
                            At the RCM 2005 conference in Clearwater, Florida conference
                            attendees were asked:

                            “If your company did the maintenance for commercial airplanes, how
                            often would you fly?”

                            Scary thought? Fortunately, most industrial maintenance managers
                            will never have to answer that question.

                            To be sure, when it comes to the understanding of maintenance and
                            the roll of Reliability Centered Maintenance, the airlines are far ahead
                            of industrial manufacturers. After all, RCM was invented by the airline
                            industry.

                            But also, in the airline business, the maintenance mission is quite
                            clear, it begins with an understanding of equipment functions and the
                            failure modes that result in functional failures and ends with a very
                            specific maintenance strategy designed to mitigate the consequences
                            of each failure mode. As a result, maintenance is viewed as a
                            reliability function instead of a repair function.

                            In viewing maintenance as a reliability function, the airline industry
                            simply charges maintenance with the following mission:

                            To keep airplanes airborne, full of passengers, and safe.

                            This mission leads to a very tight set of maintenance guidelines,
                            procedures and controls. On the other hand, inside the typical
                            manufacturing plant where maintenance is viewed as a repair, the
                            maintenance mission is not that clear.

                            For example, if a packaging line goes down for a couple of hours, that
                            may not be such a big deal. But when you’re talking about a plane
                            with hundreds of people on board, that’s a totally different story.

                            See, the fundamental difference between RCM and all previous
                            approaches to maintenance is the emphasis on two things: safety and
                            reliability. So even when you take out the safety factor, it’s obvious
                            that RCM is still the best way to go.

                            If RCM is so successful, why do some companies have failed RCM
                            efforts?




www.alliedreliability.com                           Page 6 of 18                   ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           To answer this question, Allied Reliability created the paper: Why RCM
                           Doesn’t Work – How to Avoid the 5 Biggest Mistakes that Lead to
                           False Starts and Dead Ends. In viewing the problem with a traditional
                           RCM approach, Allied Reliability offers not only the top five causes for
                           failed RCM efforts, but pro-active tasks that can be put in place to
                           eliminate the failures.

                           “RCM is Too Resource Intensive”
                           Mistake Number 1 Leading to False Starts and Dead Ends in RCM

                           RCM is often viewed as a very resource-intensive process. To perform
                           a single RCM analysis requires a substantial amount of work with
                           literally hundreds of decisions that have to be made.

                           So RCM should not be applied to every single asset you have. The
                           key is to apply it only where it’s needed.

                           For instance, there might be only about 10% of the assets in your plant
                           where you need RCM. If you apply RCM on that critical 10%, you
                           should be able to improve your overall capacity, increase output and
                           return a value much greater than the money you spend to do it.

                           How do you determine where you should apply RCM?

                           Focus on the systems that will give you the best Return on Investment
                           (ROI). Simply put, RCM is a slam dunk when it comes to return on
                           investment for critical assets. Begin you RCM effort by identifying the
                           top 10% of your most critical assets. Once this list has been identified,
                           you should now begin to measure Overall Equipment Effectiveness
                           (OEE) on these assets and performing RCM analysis on those critical
                           assets that have equipment-based operational, speed and quality
                           losses. If you have selected a critical asset, your implemented RCM
                           maintenance strategy will show measurable improvements in OEE with
                           added improvements in Health, Safety and Environmental performance
                           as well.

                           As a general rule, the success of your first implemented RCM analysis
                           will build the business case to complete RCM analysis on the
                           remainder of your critical assets.

                           Why is RCM viewed as being resource-intensive?

                           A good RCM analysis requires a number of key people to take time
                           away from their regular jobs. Subject matter experts, like operators,
                           maintainers, supervisors and trades people, will need to become a part




©2007 Allied Reliability, Inc.                      Page 7 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK


                            of your RCM effort as it’s their expertise and experience that makes
                            the process successful.

                            While some plants believe they can’t afford or even consider RCM –
                            especially in a reactive situation where the main job is to keep the plant
                            running. Companies who have successful RCM efforts in place know
                            the reality when it comes to critical assets; “We can’t afford to not do
                            RCM when it comes to our critical assets as the cost of lost
                            opportunities alone will doom our business.”

                            When we get down to the nuts and bolts of why RCM works for some
                            companies and not others we find three things all the successful efforts
                            have in common;

                               1. Leadership

                               2. Structure

                               3. Discipline

                            Companies that don’t use RCM, look for and share openly with others
                            excuses as to why a proven process didn’t work at their plant. While
                            some may view RCM as being labor intensive, companies who have
                            successful RCM efforts understand that RCM analyses performed by
                            your experts on critical assets will provide a return on investment in
                            improved equipment reliability with reduced Health, Safety, and
                            Environmental incidents and accidents.

                            It takes experience and expertise to understand your failure modes
                            and mitigate the consequences. Only your people bring both
                            experience and expertise to the table. They are the critical resources
                            able to deliver exceptional results.

                            RCM Excuse Number 1 is busted!

                            “RCM is Just too Complex”
                            The 2nd Mistake Leading to False Starts and Dead Ends
                            in RCM
                            If you’re looking for the book of excuses why RCM didn’t work at your
                            plant we have heard them all. Recently we received a call from an
                            operations manager at a mid-sized U.S. utility company. He’s part of a
                            five-member corporate team trying to improve the way they do
                            maintenance.




www.alliedreliability.com                          Page 8 of 18                   ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           Basically, their challenge is to raise availability across their fleet of
                           plants from 85% to 91%.

                           At first, he wanted to talk about some Condition Monitoring solutions.
                           It seems they have numerous plants, and quot;each one is doing
                           something different on PM and PdM.quot;

                           Then I asked a couple of questions about RCM. Quickly, his tone
                           changed from enthusiastic to reluctant. Finally, he said, “Hang on a
                           minute; I need to shut my door.”

                           quot;Lookquot;, he said, “RCM is a dirty word around here. I’m working with a
                           group that really doesn’t like RCM. What they like is condition-based.
                           So I can’t go back to them with anything that sounds like RCM.”

                           Now what’s interesting is there are four other members on the team,
                           and are all maintenance managers. So in effect, the company’s senior
                           maintenance staff has already decided NOT to use RCM as a way to
                           improve availability.

                           Why? I didn't ask, but I have a strong hunch that the complexity of an
                           RCM analysis and all the documentation required can be extremely
                           demanding. That's the main reason why manufacturers have been so
                           slow to adopt the RCM approach.

                           Reliability Centered Maintenance is a structured step by step, logical
                           process. The structure of this process, while quite simple, requires a
                           trained facilitator who has the discipline to lead the team step by step
                           through the process.

                           At first glance, the RCM process can be intimidating and we are often
                           challenged with the question; Do we really need to discuss failures to
                           this level of detail?

                           If you want to be successful in improving reliability, the answer is yes.

                           Remember the three traits of companies who have successful RCM
                           efforts? Leadership – Structure – Discipline

                           The RCM process provides the structure needed to be successful.
                           Our Allied RCM Blitz™ Practitioners provide the leadership and
                           direction through hands on mentoring that will provide the leadership
                           and discipline it takes to make RCM part of your company culture.




©2007 Allied Reliability, Inc.                       Page 9 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK


                            Some recommendations when it comes to starting a successful RCM
                            effort:

                            1. Sell team members on the benefits of RCM

                            RCM takes time and effort away from people who already have full-
                            time jobs. So you’ve got to be able to explain to them, in plain English,
                            the benefits of RCM.

                            Forget all the technical jargon. You must be able to show how RCM
                            will improve the economics, safety or quality of life at the plant.

                            Post some examples of successful RCM efforts and begin your effort
                            by getting baseline OEE measures on your critical assets. Continue to
                            measure OEE as you begin to complete and implement the tasks from
                            your RCM analyses. The success or your effort and the improved
                            OEE will sell the process.

                            2. Use TBTUF

                            Total best thinking up-front, or TBTUF, is one of the keys to successful
                            RCM. In the simplest terms, RCM is a decision-making process which
                            calls for answers to questions such as:

                            -   What is this system supposed to do?
                            -   How can it fail to do that?
                            -   What causes it to fail?
                            -   What happens when it does fail?
                            -   Can we predict or prevent that from happening?

                            Obviously, the answers must come from the people who know the
                            system: operators, maintainers, supervisors, technicians, designers
                            and manufacturers.

                            The key is to identify these experts and get their buy-in well in
                            advance.




www.alliedreliability.com                          Page 10 of 18                   ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           3. Involve the RCM team members in implementation

                           Each RCM analysis should have an Implementation Manager assigned
                           to the analysis. This person is responsible for tracking and reporting
                           the progress of your implementation to company management and the
                           RCM team. To help push the implementation forward, each task
                           identified in the RCM analysis should be assigned to a specific
                           individual and each task should have a due date for completion.

                           One way to assist in moving forward with implementation is to involve
                           the RCM team in the implementation of RCM tasks. The people
                           involved in the analysis will often take ownership in making sure the
                           tasks are implemented, scheduled and completed.

                           4. Get leaders on board

                           It is not unusual to see the least experienced and most junior
                           personnel assigned to an RCM analysis team. What does that tell
                           everyone about the project?

                           Your RCM teams should be made up of people who are viewed as:

                                 •   Experts in the process or piece of equipment being analyzed
                                 •   Respected by their peers in operations and maintenance
                                 •   Outspoken, Honest, and Open to Change

                           5. The A-B-C formula for avoiding quot;analysis paralysisquot;

                           Information overload makes it difficult, if not impossible, for people to
                           make decisions. So that's a good reason to avoid non-stop RCM
                           analysis meetings which tie up people for weeks on end.

                           Your RCM meetings should be prepped, planned, scheduled and
                           performed with the efficiency of heart bypass surgery and tying up
                           critical resources (people) for weeks on end will only doom your effort.

                           The RCM Blitz™ methodology came about as a result of recognizing
                           that RCM analyses don’t have to last for weeks and months on end.
                           The average RCM Blitz analysis lasts less than one week and by
                           Monday afternoon the following week you will have a complete
                           implementation plan in place.




©2007 Allied Reliability, Inc.                        Page 11 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK


                            Best of all, the team can start implementing the simpler changes that
                            come out of the RCM process and start showing results!

                            Debunking myth number two, “RCM is too complex”!

                            RCM is not complex, it’s structured, and as a result, this structure
                            requires a detailed plan and the leadership to see it through.

                            Moving Forward Without a Plan
                            The 3rd Mistake Leading to False Starts and Dead Ends
                            in RCM
                            One of Murphy's Law states that everything takes longer and costs
                            more than originally projected and we're afraid that's true about many
                            RCM projects.

                            The old maxim quot;time is moneyquot; most definitely applies to maintenance.

                            One sad fact we all recognize about time; You can't speed it up or slow
                            it down. When we are young we can’t wait to get older so we can drive
                            or move out on our own. When we get older we often wish we could
                            go back and change things or just slow time down to enjoy life. So
                            when it comes to time, what do we have left?

                            We have to manage time to get the most out of life and the same is
                            true when it comes to RCM. The best RCM efforts have a detailed
                            plan from start to finish and this plan is reported to everyone who has a
                            stake in the RCM effort.

                            From a 30,000-foot view, there are basically four steps to any RCM
                            project:

                            1.   Up front planning
                            2.   The RCM Analysis
                            3.   Implementation of RCM tasks
                            4.   Achieve results, benefits and return on investment

                            The secret is to consider step 3 first. Why? Because if there's no
                            execution, there will be no return on investment. So if you don't have
                            or can't get the resources needed for implementation, there's no point
                            doing any analysis.




www.alliedreliability.com                          Page 12 of 18                  ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           Now this point seems obvious, but it's often overlooked.

                           For instance, in 2001 a steel plant did a complete RCM analysis on a
                           number of critical systems in their rolling mills. But afterwards, the
                           company's management denied all requests for resources to
                           implement the results. The company later declared bankruptcy and
                           the plant was sold.

                           In another case, a big international chemical company hired a
                           consultant to facilitate RCM analysis on a troublesome process which
                           was impacting multiple plants. The analysis was completed, report
                           written and recommendations made within 3 weeks.

                           Yet two months later, the implementation still hadn't begun, and it
                           probably never will.

                           The key to having a successful RCM effort comes in understanding
                           why the two above RCM efforts failed. What did both efforts have in
                           common?

                           They failed to have a detailed plan in place to set the project up for
                           success. If you don’t have a detailed plan for success, then you can
                           plan on failure.

                           Think Days Instead of Weeks

                           Without a doubt, one of the biggest success factors in RCM is how fast
                           you can go from the analysis in step 2 to implementation in step 3.
                           The whole purpose of RCM is to determine the most cost-effective type
                           of maintenance for a particular system. So it makes sense that the
                           sooner you can implement the results of an RCM analysis, the sooner
                           you should be able to show the value.

                           In contrast, the longer it takes to implement the results of an RCM
                           analysis, the less likely the project is to succeed.

                           That's why one of the roles of an RCM Implementation Manager is to
                           push, push and push some more to keep the elapsed time between
                           analysis and implementation down to the shortest number of days
                           possible.

                           You've probably heard of the concept in time management which says
                           work expands to fill the time available. That principle will kill you in
                           RCM if you aren't careful. It's the positive pressure of tight deadlines
                           and high expectations that get and keep RCM projects in high gear.




©2007 Allied Reliability, Inc.                     Page 13 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK


                            He Who Hesitates….

                            Another costly mistake is when RCM leaders wait until all the analysis
                            are complete before they begin implementing the new maintenance
                            plan. To be sure, in most cases implementation can and should start
                            soon after analysis begins.

                            The fact is that RCM analysis teams have many quot;Ah Haquot; moments
                            when they uncover changes they know would have an immediate
                            impact ... IF immediate action was taken.

                            The secret is to treat the analysis, implementation and results steps as
                            overlapping with each other rather than in strict sequence. The ideal
                            situation is when you can begin showing real benefits of the RCM
                            process before the analysis stage has even been completed.

                            Keep Approval Chains to a Minimum

                            Finally, it's a good idea to keep the approval process as short as
                            possible in order to prevent any delays in execution. You don't want
                            anyone who is unfamiliar with the RCM process blocking progress
                            without good reason.

                            All the mechanisms should be in place to start implementing results
                            well before the analysis is complete on the first system. There can be
                            multiple activities to consider, including:

                            - Identifying and allocating resources
                            - Writing new procedures, walking-down equipment and getting
                              approvals
                            - Buying special parts and tools
                            - Training and orientation of crafts personnel on new procedures
                            - Planning and scheduling
                            - Executing new tasks

                            The reality is that some companies can take months to make small
                            decisions. That's why it's important to set aggressive timelines and
                            make everyone live by them once the changes have been approved.

                            Shall we put to bed RCM excuse number three? Rest assured, your
                            RCM effort will fail if you don’t have a plan. RCM takes time, critical
                            resources and money, so it should only be applied where it will show a
                            return on investment.




www.alliedreliability.com                         Page 14 of 18                  ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           Does that statement sound familiar? It should, we have the same
                           expectations for capital spending, yet how many capital projects move
                           forward without a plan?

                           If you want your RCM effort to be successful you will need a detailed
                           plan in place. The RCM Blitz™ method gives your RCM facilitators
                           detailed instruction on how to set your effort up for success. Prior to
                           starting your first RCM you will prepare the RCM contract that details
                           each step of process, the people involved in each step and the date it
                           will start and the date it will be completed. This contract requires
                           signatures from company management, area managers, supervision
                           and the RCM team.

                           In ten years of leading companies to successful RCM efforts, every
                           company that completed the RCM contract implemented their analysis
                           tasks, showed a return on their investment and continued with a
                           successful RCM effort. The contract is your plan for success when it
                           comes to RCM, and now that we have a plan, you can forget about
                           making mistake number three!

                           RCM is All About Condition Monitoring
                           “We don’t have it, we don’t get it, and we
                           can’t afford it”
                           The 4th Mistake Leading to False Starts and Dead Ends
                           in RCM
                           RCM is often viewed as a complex and advanced reliability tool
                           intended only for companies with advanced maintenance and reliability
                           efforts. As a result, many companies who could be successful in RCM
                           are scared away from the tool because they don’t have a predictive
                           maintenance group or their tradespeople have not been trained in
                           precision alignment or balancing.

                           As a result, they shy away from a tool that will help them build the
                           business case for using PdM and precision maintenance techniques.

                           A good RCM analysis delivers a balanced set of maintenance tasks
                           designed to ensure the inherent designed safety and reliability
                           capabilities of your asset. The key word here is balanced, each task is
                           designed to mitigate a specific failure mode with the recognition that
                           one task can not and will not cover all the failure modes for any given
                           component.




©2007 Allied Reliability, Inc.                     Page 15 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK


                            RCM is all about understanding failure and the relationship between
                            causes and effects. It’s a process that shines a light on each
                            component detailing, not only the ways it can fail, but also the ways we
                            as humans cause it to fail.

                            As part of the RCM decision making process we ask the question; Can
                            the failure be detected using On-Condition Maintenance?

                            When I ask this question regarding the failure of a high speed bearing
                            on a piece of rotating equipment, I will often get the following answer;
                            “Well, no…..we don’t have a vibration group, so we can’t detect that
                            failure.”

                            Reliability Centered Maintenance is not about the haves or have nots,
                            it’s about making the determination of what is the best thing to do. So
                            when it comes to answering the question; Is there an On-Condition
                            task that would detect the failure? The correct answer is always yes,
                            and that task is vibration analysis.

                            If we follow the RCM process and start our effort with a plan, the
                            business case to perform vibration analysis and other PdM techniques
                            on our critical assets will be a slam dunk. The cost of bringing in the
                            technology, detecting the failure, and planning and scheduling the
                            repair prior to failure will be far less than cost of an unscheduled
                            emergency failure.

                            Reliability Centered Maintenance is all about building the business
                            case for reliability. It’s about learning how to operate and maintain our
                            assets in the most efficient way possible. With that being said, I think
                            we can burry excuse number four. Every one can afford to learn and
                            apply PdM techniques to their critical assets.

                            “We Expect More From the RCM Process
                            Than We Do From Our Leaders”
                            The 5th Mistake Leading to False Starts and Dead Ends
                            in RCM
                            It’s been said in the past that one in every three RCM efforts will end in
                            failure. I think that statement is actually being very kind to RCM. I
                            would put the number to two out of every three.




www.alliedreliability.com                          Page 16 of 18                  ©2007 Allied Reliability, Inc.
How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends


                           These numbers are both sad and discouraging considering the
                           workforce in today’s manufacturing companies are both more
                           experienced and educated than the workforce Stan Nowlan and
                           Howard Heap had to work with.

                           I stated earlier that Reliability Centered Maintenance is about
                           understanding the relationship between causes and effects, and in
                           doing so we use the experience of our RCM team to identify the failure
                           modes of our assets and in turn use the RCM decision logic to identify
                           a maintenance task to mitigate each failure.

                           Using that same logic, could we not perform a RCM analysis on Why
                           RCM Efforts Fail?

                           In simple terms Reliability Centered Maintenance is Pro-Active Root
                           Cause Analysis and if we look at the causes of why RCM efforts fail,
                           one major piece of this cause map would be leadership.

                           All by itself RCM is a fantastic process, put six people through a RCM
                           analysis and they will come out of that analysis with a thorough
                           understanding of how the equipment is supposed to work and the
                           consequences of each failure mode. That knowledge has tremendous
                           value, but on its own, it won’t show a return on investment for the RCM
                           analysis. To get the value from your analyses, they must be
                           implemented.

                           While its been stated over and over that implementation is the
                           graveyard of RCM, I tend to have different belief. While your RCM
                           effort might be dead and buried because it wasn’t implemented. Your
                           leadership holds the RCM shovel and they have two choices:

                                 1. They can use the shovel to dig a grave by ignoring the process,
                                    expecting implementation to happen all on its own.

                                 2. They can use the shovel to dig the foundation for a successful
                                    RCM effort by becoming involved with the planning and
                                    execution of each step of the RCM process.

                           When it comes to successful RCM efforts, we see leaders and
                           leadership at all levels. People who understand that while the RCM
                           process will deliver the structure, it takes people to deliver the
                           leadership and discipline necessary to guarantee success in any RCM
                           initiative. With Leadership factored in….RCM really DOES work!




©2007 Allied Reliability, Inc.                        Page 17 of 18                             www.alliedreliability.com
WHY RCM DOESN’T WORK



                            About Allied Reliability
                            Allied Reliability helps companies build wealth and competitive
                            advantage through world-class predictive maintenance and reliability
                            across a global manufacturing network.

                            Founded in 1997, Allied Reliability has quickly become the largest
                            engineering firm specializing in predictive maintenance and reliability
                            engineering.

                            Today, Allied Reliability serves some of the biggest names in
                            manufacturing, including more than 200 plants and facilities in the
                            U.S., Canada, Europe and Latin America.




                            FREE Reliability Consultation

                            Every year the gap between the companies who are taking advantage
                            of reliability and the ones who aren’t gets wider.

                            That’s why you can’t afford not to make significant reliability
                            improvements in 2007. Those who prepare now will reap big dividends
                            in the future…while others will struggle to survive.

                            There are very few shortcuts. However, one is to make sure you get
                            the right help.

                            Now you can get answers to your most important questions about
                            RCM with a free, 55-minute reliability phone consultation.

                            There’s no hassle, no cost and no obligations.

                            Any information you provide is confidential and will not be shared
                            outside of our firm.

                            To take advantage of this special offer contact Allied Reliability at:

                               Phone:         888-414-5760
                               Fax:           843-414-5779
                               Email:         info@alliedreliability.com




www.alliedreliability.com                          Page 18 of 18                   ©2007 Allied Reliability, Inc.
Legal Notice
While all attempts have been made to verify information provided in this publication,
neither the author nor the publisher assumes any responsibility for errors, omissions or
contradictory interpretation of the subject matter herein.

The purchaser or reader of this publication assumes responsibility for the use of these
materials and information. Adherence to all applicable laws and regulations, including
federal, state and local governing business practices and any other aspects of doing
business in the U.S. or any other jurisdiction is the sole responsibility of the purchaser
or reader. Allied Reliability, Inc. assumes no responsibility or liability whatsoever on
behalf of any purchaser or reader of these materials.




©2007 Allied Reliability, Inc                                              www.alliedreliability.com
Allied Reliability, Inc.
       4360 Corporate Road ▪ Suite 110 ▪ Charleston, SC 29405 USA
                 Phone 888-414-5760 ▪ Fax 843-414-5779
            www.alliedreliability.com ▪ info@alliedreliability.com


Allied Reliability helps companies build wealth and competitive advantage through world-
   class predictive maintenance and reliability across a global manufacturing network.

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RCM copyright notice guide

  • 1.
  • 2.
  • 3. Copyright Notice Copyright 2008 Allied Reliability, Inc. All rights reserved. Any unauthorized use, sharing, reproduction or distribution of these materials by any means, electronic, mechanical, or otherwise is strictly prohibited. No portion of these materials may be reproduced in any manner whatsoever, without the express written consent of the publisher. To obtain permission, please contact: Allied Reliability, Inc. 4360 Corporate Rd #110 Charleston, SC 29405 Phone 888-414-5760 Fax 843-414-5779 info@alliedreliability.com www.alliedreliability.com 3rd Edition January 25, 2008
  • 4.
  • 5. WHY RCM DOESN’T WORK How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends Table of Contents RCM Made Simple…………………………………………………........ 3 Does RCM Work for Manufacturers?................................................. 6 RCM is too Resource Intensive Mistake #1………………………………………………………… 7 RCM is Just too Complex Mistake #2………………………………………………………… 8 Moving Forward Without A Plan Mistake #3………………………………………………………… 12 RCM is All About Condition Monitoring Mistake #4………………………………………………………... 15 We Expect More From The RCM Process Than We Do From Our Leaders Mistake #5….…………………………………………………….. 16 About Allied Reliability…………………………………………………... 18 ©2007 Allied Reliability, Inc Page 1 of 18 www.alliedreliability.com
  • 6. WHY RCM DOESN’T WORK Introduction Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn’t work, what needs to change and how to put RCM to work at your company so it doesn’t become another Resource Consuming Monster. www.alliedreliability.com Page 2 of 18 ©2007 Allied Reliability, Inc.
  • 7. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends RCM Made Simple It has been almost 30 years since Stanley Nowlan and Howard Heap published quot;Reliability Centered Maintenancequot;, the ground-breaking study that changed maintenance forever. Yet myth, mystery and confusion about RCM still abound. So let's begin with the basic truths. To paraphrase RCM practitioner, Doug Plucknette, of Allied Reliability, RCM is a structured process developed to ensure the designed safety and reliability capabilities of a process or piece of equipment. The beauty of understanding the RCM process is it can be applied to virtually any physical asset in any plant around the world. RCM's roots go back to the early 1960's, when the commercial airline companies were considering buying the new jumbo jet, the Boeing 747. At the time, the airlines religiously practiced time-based preventive maintenance. Why? Because the conventional wisdom was that equipment wears out over time. So that meant taking planes out of service for maintenance every 1,000, 5,000 or 10,000 hours. But the problem with the 747's was the amount of maintenance specified by federal regulators was three times more than the maintenance required for Boeing 707's. That meant more time in maintenance, more time out of service, and a huge disruption to operations. Clearly, the airlines' traditional approach to maintenance would not be economically feasible for the new jumbo jets. So the airlines had two choices: Either buy a larger fleet of planes or develop a more economical approach to maintenance. That's why United Airlines led a task force to re-evaluate the concept of preventive maintenance and determine the most economic strategy, without compromising safety. The result was the process that we now know as RCM, which was successfully employed on the 747 and all subsequent jet aircraft. ©2007 Allied Reliability, Inc. Page 3 of 18 www.alliedreliability.com
  • 8. WHY RCM DOESN’T WORK Who Developed RCM? United, along with and Boeing Aircraft Corporation, were the early pioneers of RCM. Other airlines also considering buying the new 747's joined the task force and contributed to the process. But it was Boeing and United who took the lead in developing a logical, rational approach to maintenance that would also be acceptable to the federal regulators. In 1976, the U.S. Department of Defense contracted with United to publish how airlines develop maintenance programs. The result was quot;Reliability Centered Maintenancequot;, a landmark 495-page report by Stanley Nowlan and Howard Heap, which described the RCM methodology developed for the Boeing 747, Douglas DC-10 and Lockheed 1011. (Nowlan was the Director of Maintenance Analysis for United; Heap was United's Manager of Maintenance Program Planning.) In 1978, the Defense Department placed the report in the public domain for use by anyone interested in it. How RCM Revolutionized Maintenance The key to RCM was abandoning the philosophy of quot;preserve- equipmentquot; in favor of quot;preserve-functionquot;. Simply put, equipment became the means to an end, not the end in itself. In addition, Nowlan and Heap concluded that a maintenance policy based on operating age would have little, if any, impact on failure rates. Thus, applying time-based maintenance on equipment which has no quot;wear-outquot; pattern was futile. This forced a change in philosophy from, quot;It wasn't broke, but we fixed it anywayquot; to quot;If it ain't broke, don't fix itquot;. Nowlan and Heap also concluded that: - Time-based maintenance works only for a small percentage of components, and then only when there is solid information on their quot;wear-outquot; characteristics”. - Condition Based Maintenance (CBM) is the most-preferred option. That means monitoring, observing and taking non-intrusive actions, such as lubricating and cleaning, until a condition signals that corrective action is necessary. www.alliedreliability.com Page 4 of 18 ©2007 Allied Reliability, Inc.
  • 9. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends - Run-to-failure is a viable tactic in situations when there is no safety and little economic impact. - In a significant number of situations, the very act of maintenance itself causes subsequent failure of the equipment. - Non-intrusive maintenance tasks should be used instead of intrusive maintenance whenever possible. In other words, don't do any maintenance, except monitoring and non-intrusive sustaining actions, until condition directs intrusive corrective action. RCM Pitfalls In the last 40 years, no better method than RCM has been found for determining what maintenance should be performed. Four statistically significant studies have confirmed the validity of RCM. Yet, in a survey conducted by Reliabilityweb.com in 2005, several companies offered the following excuses when it came to their failure to begin or implement RCM as a reliability tool. quot;Mining, like all industries, wants results right away, not in 6 months or a year. The classical RCM process is too time and resource intense.quot; quot;RCM is a great tool but very resource intensive.quot; quot;100% reliability is extremely expensive, difficult to attain, and not necessarily the right answer.quot; quot;RCM is misunderstood to be software.quot; quot;In the beginning, it was hard. And it is still a challenge to steer the mind-set toward more condition-based maintenance than time-based.quot; quot;We always ran into the problem with implementation. In the few places where we implemented it successfully, it was at the maintenance level. And recognition for it was non-existent.quot; quot;The system is very strong but too high level ...quot; The truth is, there are many pitfalls in RCM. But few get revealed when an RCM project fails. You see, nobody wants to write an article or present a paper at a conference which reveals how money was wasted and great visions were never realized. ©2007 Allied Reliability, Inc. Page 5 of 18 www.alliedreliability.com
  • 10. WHY RCM DOESN’T WORK Does RCM Work for Manufacturers? At the RCM 2005 conference in Clearwater, Florida conference attendees were asked: “If your company did the maintenance for commercial airplanes, how often would you fly?” Scary thought? Fortunately, most industrial maintenance managers will never have to answer that question. To be sure, when it comes to the understanding of maintenance and the roll of Reliability Centered Maintenance, the airlines are far ahead of industrial manufacturers. After all, RCM was invented by the airline industry. But also, in the airline business, the maintenance mission is quite clear, it begins with an understanding of equipment functions and the failure modes that result in functional failures and ends with a very specific maintenance strategy designed to mitigate the consequences of each failure mode. As a result, maintenance is viewed as a reliability function instead of a repair function. In viewing maintenance as a reliability function, the airline industry simply charges maintenance with the following mission: To keep airplanes airborne, full of passengers, and safe. This mission leads to a very tight set of maintenance guidelines, procedures and controls. On the other hand, inside the typical manufacturing plant where maintenance is viewed as a repair, the maintenance mission is not that clear. For example, if a packaging line goes down for a couple of hours, that may not be such a big deal. But when you’re talking about a plane with hundreds of people on board, that’s a totally different story. See, the fundamental difference between RCM and all previous approaches to maintenance is the emphasis on two things: safety and reliability. So even when you take out the safety factor, it’s obvious that RCM is still the best way to go. If RCM is so successful, why do some companies have failed RCM efforts? www.alliedreliability.com Page 6 of 18 ©2007 Allied Reliability, Inc.
  • 11. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends To answer this question, Allied Reliability created the paper: Why RCM Doesn’t Work – How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends. In viewing the problem with a traditional RCM approach, Allied Reliability offers not only the top five causes for failed RCM efforts, but pro-active tasks that can be put in place to eliminate the failures. “RCM is Too Resource Intensive” Mistake Number 1 Leading to False Starts and Dead Ends in RCM RCM is often viewed as a very resource-intensive process. To perform a single RCM analysis requires a substantial amount of work with literally hundreds of decisions that have to be made. So RCM should not be applied to every single asset you have. The key is to apply it only where it’s needed. For instance, there might be only about 10% of the assets in your plant where you need RCM. If you apply RCM on that critical 10%, you should be able to improve your overall capacity, increase output and return a value much greater than the money you spend to do it. How do you determine where you should apply RCM? Focus on the systems that will give you the best Return on Investment (ROI). Simply put, RCM is a slam dunk when it comes to return on investment for critical assets. Begin you RCM effort by identifying the top 10% of your most critical assets. Once this list has been identified, you should now begin to measure Overall Equipment Effectiveness (OEE) on these assets and performing RCM analysis on those critical assets that have equipment-based operational, speed and quality losses. If you have selected a critical asset, your implemented RCM maintenance strategy will show measurable improvements in OEE with added improvements in Health, Safety and Environmental performance as well. As a general rule, the success of your first implemented RCM analysis will build the business case to complete RCM analysis on the remainder of your critical assets. Why is RCM viewed as being resource-intensive? A good RCM analysis requires a number of key people to take time away from their regular jobs. Subject matter experts, like operators, maintainers, supervisors and trades people, will need to become a part ©2007 Allied Reliability, Inc. Page 7 of 18 www.alliedreliability.com
  • 12. WHY RCM DOESN’T WORK of your RCM effort as it’s their expertise and experience that makes the process successful. While some plants believe they can’t afford or even consider RCM – especially in a reactive situation where the main job is to keep the plant running. Companies who have successful RCM efforts in place know the reality when it comes to critical assets; “We can’t afford to not do RCM when it comes to our critical assets as the cost of lost opportunities alone will doom our business.” When we get down to the nuts and bolts of why RCM works for some companies and not others we find three things all the successful efforts have in common; 1. Leadership 2. Structure 3. Discipline Companies that don’t use RCM, look for and share openly with others excuses as to why a proven process didn’t work at their plant. While some may view RCM as being labor intensive, companies who have successful RCM efforts understand that RCM analyses performed by your experts on critical assets will provide a return on investment in improved equipment reliability with reduced Health, Safety, and Environmental incidents and accidents. It takes experience and expertise to understand your failure modes and mitigate the consequences. Only your people bring both experience and expertise to the table. They are the critical resources able to deliver exceptional results. RCM Excuse Number 1 is busted! “RCM is Just too Complex” The 2nd Mistake Leading to False Starts and Dead Ends in RCM If you’re looking for the book of excuses why RCM didn’t work at your plant we have heard them all. Recently we received a call from an operations manager at a mid-sized U.S. utility company. He’s part of a five-member corporate team trying to improve the way they do maintenance. www.alliedreliability.com Page 8 of 18 ©2007 Allied Reliability, Inc.
  • 13. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends Basically, their challenge is to raise availability across their fleet of plants from 85% to 91%. At first, he wanted to talk about some Condition Monitoring solutions. It seems they have numerous plants, and quot;each one is doing something different on PM and PdM.quot; Then I asked a couple of questions about RCM. Quickly, his tone changed from enthusiastic to reluctant. Finally, he said, “Hang on a minute; I need to shut my door.” quot;Lookquot;, he said, “RCM is a dirty word around here. I’m working with a group that really doesn’t like RCM. What they like is condition-based. So I can’t go back to them with anything that sounds like RCM.” Now what’s interesting is there are four other members on the team, and are all maintenance managers. So in effect, the company’s senior maintenance staff has already decided NOT to use RCM as a way to improve availability. Why? I didn't ask, but I have a strong hunch that the complexity of an RCM analysis and all the documentation required can be extremely demanding. That's the main reason why manufacturers have been so slow to adopt the RCM approach. Reliability Centered Maintenance is a structured step by step, logical process. The structure of this process, while quite simple, requires a trained facilitator who has the discipline to lead the team step by step through the process. At first glance, the RCM process can be intimidating and we are often challenged with the question; Do we really need to discuss failures to this level of detail? If you want to be successful in improving reliability, the answer is yes. Remember the three traits of companies who have successful RCM efforts? Leadership – Structure – Discipline The RCM process provides the structure needed to be successful. Our Allied RCM Blitz™ Practitioners provide the leadership and direction through hands on mentoring that will provide the leadership and discipline it takes to make RCM part of your company culture. ©2007 Allied Reliability, Inc. Page 9 of 18 www.alliedreliability.com
  • 14. WHY RCM DOESN’T WORK Some recommendations when it comes to starting a successful RCM effort: 1. Sell team members on the benefits of RCM RCM takes time and effort away from people who already have full- time jobs. So you’ve got to be able to explain to them, in plain English, the benefits of RCM. Forget all the technical jargon. You must be able to show how RCM will improve the economics, safety or quality of life at the plant. Post some examples of successful RCM efforts and begin your effort by getting baseline OEE measures on your critical assets. Continue to measure OEE as you begin to complete and implement the tasks from your RCM analyses. The success or your effort and the improved OEE will sell the process. 2. Use TBTUF Total best thinking up-front, or TBTUF, is one of the keys to successful RCM. In the simplest terms, RCM is a decision-making process which calls for answers to questions such as: - What is this system supposed to do? - How can it fail to do that? - What causes it to fail? - What happens when it does fail? - Can we predict or prevent that from happening? Obviously, the answers must come from the people who know the system: operators, maintainers, supervisors, technicians, designers and manufacturers. The key is to identify these experts and get their buy-in well in advance. www.alliedreliability.com Page 10 of 18 ©2007 Allied Reliability, Inc.
  • 15. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends 3. Involve the RCM team members in implementation Each RCM analysis should have an Implementation Manager assigned to the analysis. This person is responsible for tracking and reporting the progress of your implementation to company management and the RCM team. To help push the implementation forward, each task identified in the RCM analysis should be assigned to a specific individual and each task should have a due date for completion. One way to assist in moving forward with implementation is to involve the RCM team in the implementation of RCM tasks. The people involved in the analysis will often take ownership in making sure the tasks are implemented, scheduled and completed. 4. Get leaders on board It is not unusual to see the least experienced and most junior personnel assigned to an RCM analysis team. What does that tell everyone about the project? Your RCM teams should be made up of people who are viewed as: • Experts in the process or piece of equipment being analyzed • Respected by their peers in operations and maintenance • Outspoken, Honest, and Open to Change 5. The A-B-C formula for avoiding quot;analysis paralysisquot; Information overload makes it difficult, if not impossible, for people to make decisions. So that's a good reason to avoid non-stop RCM analysis meetings which tie up people for weeks on end. Your RCM meetings should be prepped, planned, scheduled and performed with the efficiency of heart bypass surgery and tying up critical resources (people) for weeks on end will only doom your effort. The RCM Blitz™ methodology came about as a result of recognizing that RCM analyses don’t have to last for weeks and months on end. The average RCM Blitz analysis lasts less than one week and by Monday afternoon the following week you will have a complete implementation plan in place. ©2007 Allied Reliability, Inc. Page 11 of 18 www.alliedreliability.com
  • 16. WHY RCM DOESN’T WORK Best of all, the team can start implementing the simpler changes that come out of the RCM process and start showing results! Debunking myth number two, “RCM is too complex”! RCM is not complex, it’s structured, and as a result, this structure requires a detailed plan and the leadership to see it through. Moving Forward Without a Plan The 3rd Mistake Leading to False Starts and Dead Ends in RCM One of Murphy's Law states that everything takes longer and costs more than originally projected and we're afraid that's true about many RCM projects. The old maxim quot;time is moneyquot; most definitely applies to maintenance. One sad fact we all recognize about time; You can't speed it up or slow it down. When we are young we can’t wait to get older so we can drive or move out on our own. When we get older we often wish we could go back and change things or just slow time down to enjoy life. So when it comes to time, what do we have left? We have to manage time to get the most out of life and the same is true when it comes to RCM. The best RCM efforts have a detailed plan from start to finish and this plan is reported to everyone who has a stake in the RCM effort. From a 30,000-foot view, there are basically four steps to any RCM project: 1. Up front planning 2. The RCM Analysis 3. Implementation of RCM tasks 4. Achieve results, benefits and return on investment The secret is to consider step 3 first. Why? Because if there's no execution, there will be no return on investment. So if you don't have or can't get the resources needed for implementation, there's no point doing any analysis. www.alliedreliability.com Page 12 of 18 ©2007 Allied Reliability, Inc.
  • 17. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends Now this point seems obvious, but it's often overlooked. For instance, in 2001 a steel plant did a complete RCM analysis on a number of critical systems in their rolling mills. But afterwards, the company's management denied all requests for resources to implement the results. The company later declared bankruptcy and the plant was sold. In another case, a big international chemical company hired a consultant to facilitate RCM analysis on a troublesome process which was impacting multiple plants. The analysis was completed, report written and recommendations made within 3 weeks. Yet two months later, the implementation still hadn't begun, and it probably never will. The key to having a successful RCM effort comes in understanding why the two above RCM efforts failed. What did both efforts have in common? They failed to have a detailed plan in place to set the project up for success. If you don’t have a detailed plan for success, then you can plan on failure. Think Days Instead of Weeks Without a doubt, one of the biggest success factors in RCM is how fast you can go from the analysis in step 2 to implementation in step 3. The whole purpose of RCM is to determine the most cost-effective type of maintenance for a particular system. So it makes sense that the sooner you can implement the results of an RCM analysis, the sooner you should be able to show the value. In contrast, the longer it takes to implement the results of an RCM analysis, the less likely the project is to succeed. That's why one of the roles of an RCM Implementation Manager is to push, push and push some more to keep the elapsed time between analysis and implementation down to the shortest number of days possible. You've probably heard of the concept in time management which says work expands to fill the time available. That principle will kill you in RCM if you aren't careful. It's the positive pressure of tight deadlines and high expectations that get and keep RCM projects in high gear. ©2007 Allied Reliability, Inc. Page 13 of 18 www.alliedreliability.com
  • 18. WHY RCM DOESN’T WORK He Who Hesitates…. Another costly mistake is when RCM leaders wait until all the analysis are complete before they begin implementing the new maintenance plan. To be sure, in most cases implementation can and should start soon after analysis begins. The fact is that RCM analysis teams have many quot;Ah Haquot; moments when they uncover changes they know would have an immediate impact ... IF immediate action was taken. The secret is to treat the analysis, implementation and results steps as overlapping with each other rather than in strict sequence. The ideal situation is when you can begin showing real benefits of the RCM process before the analysis stage has even been completed. Keep Approval Chains to a Minimum Finally, it's a good idea to keep the approval process as short as possible in order to prevent any delays in execution. You don't want anyone who is unfamiliar with the RCM process blocking progress without good reason. All the mechanisms should be in place to start implementing results well before the analysis is complete on the first system. There can be multiple activities to consider, including: - Identifying and allocating resources - Writing new procedures, walking-down equipment and getting approvals - Buying special parts and tools - Training and orientation of crafts personnel on new procedures - Planning and scheduling - Executing new tasks The reality is that some companies can take months to make small decisions. That's why it's important to set aggressive timelines and make everyone live by them once the changes have been approved. Shall we put to bed RCM excuse number three? Rest assured, your RCM effort will fail if you don’t have a plan. RCM takes time, critical resources and money, so it should only be applied where it will show a return on investment. www.alliedreliability.com Page 14 of 18 ©2007 Allied Reliability, Inc.
  • 19. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends Does that statement sound familiar? It should, we have the same expectations for capital spending, yet how many capital projects move forward without a plan? If you want your RCM effort to be successful you will need a detailed plan in place. The RCM Blitz™ method gives your RCM facilitators detailed instruction on how to set your effort up for success. Prior to starting your first RCM you will prepare the RCM contract that details each step of process, the people involved in each step and the date it will start and the date it will be completed. This contract requires signatures from company management, area managers, supervision and the RCM team. In ten years of leading companies to successful RCM efforts, every company that completed the RCM contract implemented their analysis tasks, showed a return on their investment and continued with a successful RCM effort. The contract is your plan for success when it comes to RCM, and now that we have a plan, you can forget about making mistake number three! RCM is All About Condition Monitoring “We don’t have it, we don’t get it, and we can’t afford it” The 4th Mistake Leading to False Starts and Dead Ends in RCM RCM is often viewed as a complex and advanced reliability tool intended only for companies with advanced maintenance and reliability efforts. As a result, many companies who could be successful in RCM are scared away from the tool because they don’t have a predictive maintenance group or their tradespeople have not been trained in precision alignment or balancing. As a result, they shy away from a tool that will help them build the business case for using PdM and precision maintenance techniques. A good RCM analysis delivers a balanced set of maintenance tasks designed to ensure the inherent designed safety and reliability capabilities of your asset. The key word here is balanced, each task is designed to mitigate a specific failure mode with the recognition that one task can not and will not cover all the failure modes for any given component. ©2007 Allied Reliability, Inc. Page 15 of 18 www.alliedreliability.com
  • 20. WHY RCM DOESN’T WORK RCM is all about understanding failure and the relationship between causes and effects. It’s a process that shines a light on each component detailing, not only the ways it can fail, but also the ways we as humans cause it to fail. As part of the RCM decision making process we ask the question; Can the failure be detected using On-Condition Maintenance? When I ask this question regarding the failure of a high speed bearing on a piece of rotating equipment, I will often get the following answer; “Well, no…..we don’t have a vibration group, so we can’t detect that failure.” Reliability Centered Maintenance is not about the haves or have nots, it’s about making the determination of what is the best thing to do. So when it comes to answering the question; Is there an On-Condition task that would detect the failure? The correct answer is always yes, and that task is vibration analysis. If we follow the RCM process and start our effort with a plan, the business case to perform vibration analysis and other PdM techniques on our critical assets will be a slam dunk. The cost of bringing in the technology, detecting the failure, and planning and scheduling the repair prior to failure will be far less than cost of an unscheduled emergency failure. Reliability Centered Maintenance is all about building the business case for reliability. It’s about learning how to operate and maintain our assets in the most efficient way possible. With that being said, I think we can burry excuse number four. Every one can afford to learn and apply PdM techniques to their critical assets. “We Expect More From the RCM Process Than We Do From Our Leaders” The 5th Mistake Leading to False Starts and Dead Ends in RCM It’s been said in the past that one in every three RCM efforts will end in failure. I think that statement is actually being very kind to RCM. I would put the number to two out of every three. www.alliedreliability.com Page 16 of 18 ©2007 Allied Reliability, Inc.
  • 21. How to Avoid the 5 Biggest Mistakes that Lead to False Starts and Dead Ends These numbers are both sad and discouraging considering the workforce in today’s manufacturing companies are both more experienced and educated than the workforce Stan Nowlan and Howard Heap had to work with. I stated earlier that Reliability Centered Maintenance is about understanding the relationship between causes and effects, and in doing so we use the experience of our RCM team to identify the failure modes of our assets and in turn use the RCM decision logic to identify a maintenance task to mitigate each failure. Using that same logic, could we not perform a RCM analysis on Why RCM Efforts Fail? In simple terms Reliability Centered Maintenance is Pro-Active Root Cause Analysis and if we look at the causes of why RCM efforts fail, one major piece of this cause map would be leadership. All by itself RCM is a fantastic process, put six people through a RCM analysis and they will come out of that analysis with a thorough understanding of how the equipment is supposed to work and the consequences of each failure mode. That knowledge has tremendous value, but on its own, it won’t show a return on investment for the RCM analysis. To get the value from your analyses, they must be implemented. While its been stated over and over that implementation is the graveyard of RCM, I tend to have different belief. While your RCM effort might be dead and buried because it wasn’t implemented. Your leadership holds the RCM shovel and they have two choices: 1. They can use the shovel to dig a grave by ignoring the process, expecting implementation to happen all on its own. 2. They can use the shovel to dig the foundation for a successful RCM effort by becoming involved with the planning and execution of each step of the RCM process. When it comes to successful RCM efforts, we see leaders and leadership at all levels. People who understand that while the RCM process will deliver the structure, it takes people to deliver the leadership and discipline necessary to guarantee success in any RCM initiative. With Leadership factored in….RCM really DOES work! ©2007 Allied Reliability, Inc. Page 17 of 18 www.alliedreliability.com
  • 22. WHY RCM DOESN’T WORK About Allied Reliability Allied Reliability helps companies build wealth and competitive advantage through world-class predictive maintenance and reliability across a global manufacturing network. Founded in 1997, Allied Reliability has quickly become the largest engineering firm specializing in predictive maintenance and reliability engineering. Today, Allied Reliability serves some of the biggest names in manufacturing, including more than 200 plants and facilities in the U.S., Canada, Europe and Latin America. FREE Reliability Consultation Every year the gap between the companies who are taking advantage of reliability and the ones who aren’t gets wider. That’s why you can’t afford not to make significant reliability improvements in 2007. Those who prepare now will reap big dividends in the future…while others will struggle to survive. There are very few shortcuts. However, one is to make sure you get the right help. Now you can get answers to your most important questions about RCM with a free, 55-minute reliability phone consultation. There’s no hassle, no cost and no obligations. Any information you provide is confidential and will not be shared outside of our firm. To take advantage of this special offer contact Allied Reliability at: Phone: 888-414-5760 Fax: 843-414-5779 Email: info@alliedreliability.com www.alliedreliability.com Page 18 of 18 ©2007 Allied Reliability, Inc.
  • 23. Legal Notice While all attempts have been made to verify information provided in this publication, neither the author nor the publisher assumes any responsibility for errors, omissions or contradictory interpretation of the subject matter herein. The purchaser or reader of this publication assumes responsibility for the use of these materials and information. Adherence to all applicable laws and regulations, including federal, state and local governing business practices and any other aspects of doing business in the U.S. or any other jurisdiction is the sole responsibility of the purchaser or reader. Allied Reliability, Inc. assumes no responsibility or liability whatsoever on behalf of any purchaser or reader of these materials. ©2007 Allied Reliability, Inc www.alliedreliability.com
  • 24. Allied Reliability, Inc. 4360 Corporate Road ▪ Suite 110 ▪ Charleston, SC 29405 USA Phone 888-414-5760 ▪ Fax 843-414-5779 www.alliedreliability.com ▪ info@alliedreliability.com Allied Reliability helps companies build wealth and competitive advantage through world- class predictive maintenance and reliability across a global manufacturing network.