By the end of this programme, participants will:
- Understand the principles of Reliability Centered Maintenance (RCM) and its application to industrial equipment.
- Learn how to identify critical equipment and analyze potential failure modes.
- Develop effective maintenance strategies that improve equipment reliability.
- Prioritize maintenance tasks to optimize resources and minimize downtime.
- Apply RCM techniques through case studies and hands-on exercises in various industrial settings.
- Gain a foundational understanding of process engineering, reactor design, piping, fluid flow, and mass/energy balances in the context of RCM.
DAY 1
Introduction to RCM and Project Initiation
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- History and Overview of RCM
- Expectations from RCM
- Who Should Implement RCM
- Applications and Benefits
- Published Guidelines for RCM
- Project Initiation
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- Preparing for the Analysis
- Selecting Equipment for Analysis
- Criticality Factors and the Decision Process
- Simple Reliability
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- Integrating Reliability into RCM
- Identifying Reliability Information in Your Organization
DAY 2
Reliability, Maintainability, and Failure Analysis
- Reliability and Maintainability
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- Using Reliability Information for Maintenance Planning
- Functions and Functional Failures
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- Identifying Functions and Functional Failures
- Evaluating the Consequences and Effects of Failure
- Published Logic Diagrams
- Identifying Failure Causes (Failure Modes)
- The “Can-Want” Model and Hidden Failures
- Failure Mode and Effects Analysis (FMEA)
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- Calculating Risk Priority Numbers (RPNs)
- Criticality Analysis
- Managing Current Controls and Recommended Actions
- Introduction to APQP
DAY 3
Maintenance Strategy Selection
- Maintenance Strategy Exercise
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- Failure Characteristics Analysis (FCA)
- Selecting Maintenance Strategies
- Evaluating Maintenance Task Alternatives
- Task Selection Questions and Best Practices
- Maintenance Strategy Options
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- Run-to-Failure, Repair/Replacement, Service Tasks
- Failure-Finding Inspections and On-Condition Inspections
- One-Time Tasks
- Calculating Optimum Maintenance Intervals
DAY 4
RCM Methodologies and Software
- RCM Methodologies and Application
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- Benefits of Automated Software for RCM
- Overview of RCM++ Software
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- Organizing Information in Databases and Projects
- Working with Databases and Login Security
- Customizing the Interface with Profiles and Libraries
- RCM Logic Diagrams and Data Field Management
DAY 5
Practical Implementation and Final Review
- Working with Views and Data Entry Shortcuts
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- Hierarchical, Worksheet, and Filtered Views
- Data Entry Shortcuts: Copy/Paste, Import/Export
- Supporting RCM Logic
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- Equipment Selection, Failure Effect Categorization, Task Selection
- RCM Structure Methods
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- Zonal Inspections and Practical Application
- Industry Experience with RCM
- Summary of Critical Success Factors
- Distribution of Reference Materials
- End of Course Review and Questions
