Quote: Originally posted by Rolly12: Steve, I appreciate your input. When it comes to establishing the operating context of a plant during its commissioning stage, should I refer to the design manual or look at similar plants for guidance based on their operational experiences? Regards, Rolly. To determine the operating context, the company should consider anticipated market demands and expectations. This will provide insight into the required throughput of the plant. Understanding the throughput requirements will help in identifying the operational needs of the equipment, including factors such as equipment reliability and maintenance time estimates. While these considerations may be based on assumptions, they serve as a starting point for further analysis. Operating without establishing the context may result in suboptimal decisions compared to using an assumption-based operating context aligned with the business's needs. I hope this information is helpful. Rob
Rolly, I fully agree with the consensus that establishing the Operating Context is crucial at the onset of a Reliability Centered Maintenance (RCM) process. During the commissioning or pre-construction phase, the design basis plays a vital role in defining the operating context. Gathering insights on operational parameters and expectations for the new plant from operations management is essential. It is imperative to assess the environmental conditions in which the system will be operating. Furthermore, considering the expertise, experience, and availability of the operating and maintenance team is key. Determining the level of operator and computer monitoring required is also important.
All these factors, and more, will influence the functions to be included and the types of failure modes to be covered in the RCM analysis. I believe that conducting RCM during the design or commissioning phase is even more critical than for existing assets, as it sets the foundation for sound operating and maintenance practices. Failing to consider real-world conditions, such as environmental factors or maintenance crew capabilities, can lead to overlooking important functions and failure modes.
When assisting a team in drafting an operating context, I emphasize detailing process parameters and performance expectations. I encourage the team and management to communicate their objectives and concerns regarding the system. Often, these concerns highlight potential risks that may not have been thoroughly addressed during the design phase, such as single points of failure. Addressing these issues upfront through RCM allows for effective risk management strategies to be developed.
In summary, establishing a comprehensive Operating Context is crucial for ensuring the effectiveness of RCM and mitigating risks in system operation and maintenance. Shelley.
When preparing a maintenance strategy through Reliability-Centered Maintenance (RCM), it is essential to thoroughly define the operating context. This includes outlining how the plant will be operated to ensure reliability and profitability. The project team must not only focus on the hardware aspects but also consider the overall operation and maintenance philosophy. These documents are crucial in determining how the plant will meet its Return on Investment goals. Without a clear understanding of the operating context, conducting an RCM study would be futile and a waste of resources. It is important to consider the valuable insights provided by Steve, Shelley, and other experts in this field.
- 27-07-2024
- Frances Fisher
I believed that the design basis document would include essential information about the operating environment. This document is vital for understanding the context in which the system will be operating.
Dear Vee, Steve, Shelley, Delby, and everyone, I wanted to express my gratitude for your response and valuable insights. The design documents will be crucial in defining the operational framework of a plant that is not yet fully functional. By the way, have you heard the unfortunate news about the passing of Charles Latino? His contribution to the world of reliability will be greatly missed. Sending my heartfelt regards, [Your Name]
I believed that Reliability Centered Maintenance (RCM) was typically implemented for new aircraft during the design phase to assess economic feasibility, rather than after they are already in service. How were they able to determine the operational context in this case?
- 27-07-2024
- Shawn Thompson
When designing aircraft, it is important to consider the specific operating conditions they will be used in. Economic factors are taken into account before conducting maintenance analysis. Reliability-centered maintenance (RCM) analysis is an ongoing process that continues after aircraft are in service, as operating conditions can change and impact maintenance strategies. Aircraft designs are constantly evolving to meet the changing needs of customers and the modifications made to the aircraft. In the case of military aircraft, the initial operating criteria may shift within the first few years of service due to new requirements and missions. This calls for a reevaluation of the maintenance approach as a whole. Ken Culverson.
I concur with Ken that prior to acquiring new equipment, an economic analysis is typically conducted to assess the potential output, profitability, and growth projections. This analysis is crucial in determining the feasibility of the investment. Neglecting to perform such an analysis would be a risky leap of faith.
When producing capital equipment items like Cars, Airplanes, Pumps or Video Recorders, designers take into account a wide range of operating conditions. This means that a Mercedes Benz car, for example, is designed to function in both Alaskan winters and the scorching summers of Saudi Arabia. The maintenance requirements for such equipment are tailored to accommodate these extreme operating environments, leading to vendors providing maintenance manuals that cover all possibilities. It is important for us, as the users, to define our specific Operating Context since only we understand how the equipment will be used and what our expectations are. This is crucial in the Reliability-Centered Maintenance (RCM) process, as the first step involves defining the equipment's Function and setting Performance Standards based on our unique Operating Context. By doing so, we can establish realistic performance expectations that may differ from the vendor's built-in standards. This personalized approach ensures that maintenance efforts are neither excessive nor insufficient. While some may argue that defining the Function is unnecessary in RCM studies, I believe that it is essential for optimizing equipment performance. Each individual is entitled to their own perspective on this matter.
Neil Bloom completely agrees with Vee's response regarding the importance of design parameters and functions. Let's delve deeper into how a function should be defined. Functions outline the tasks a component needs to achieve, explaining why it was installed in the first place. Preserving these functions is crucial in any maintenance program. Components often have multiple functions, including both regular operations and emergency tasks. Defining functions helps identify potential failure modes and their consequences. It's essential to clearly define what constitutes a functional failure based on the specific concerns of your facility.
For instance, a common pump's function may be described as providing a flow of 200 gal/min at 285 psig and 87F. But what happens if it only delivers 199 gal/min at 284 psig and 86F? Is this truly a failure? In most cases, it isn't unless critical circumstances like in the space shuttle require precise specifications. For the majority of pumps in typical facilities, a more general function like "maintaining tank inventory at a consistent level" may be more suitable.
In conclusion, without specific regulatory requirements, you should define functions based on performance standards set by you as the facility owner and RCM program manager. Regards, Neil Bloom, Author of "Reliability Centered Maintenance – Implementation Made Simple" by McGraw-Hill.
quote: "Ensure optimal tank inventory levels by maintaining a consistent flow." Neil, why spend time stating the obvious? What additional value is provided beyond simply outlining functional failures and failure modes? Regards, Steve
Hi Steve, it's always great to hear from you. When defining a function, you have the flexibility to choose the starting point. However, it is important to consider that the more strict the definition, the more stringent the functional failure becomes. For example, if your function is to "provide flow at 200 gal/min at 285 psig and a temperature of 87F," then a pump outputting only 199 gal/min would not necessarily be considered a failure. The definition of a function is determined by you as the plant owner and RCM program owner. Just like a razor blade that no longer meets manufacturer specifications after the first use, it doesn't necessarily mean it has failed. The key is to define the function that you want to preserve and determine when a component has failed to meet its intended function.
SAE JA1011 supports the idea that a function should be defined at a performance level that makes sense to the plant owner, so that any deviation from that standard is considered a failure. The level of specificity in defining a function is up to you. If you feel that "provides sufficient flow" is too vague, you can add additional performance criteria. In most cases, functional definitions like "provides sufficient flow" are sufficient, even in critical environments like nuclear power plants. Thank you, Neil Bloom, Author of "Reliability Centered Maintenance – Implementation Made Simple" published by McGraw-Hill.
Appreciate all the detailed explanations. It is essential to conduct economic viability analysis before commencing any project. According to the MSG documents, Reliability-Centered Maintenance (RCM) was performed to address the significant maintenance expenses linked to the new airplanes, compared to the previous maintenance program in place. The RCM analysis will continue to adapt throughout the aircraft's lifespan to accommodate any changes.
In my opinion, when it comes to RCM (Reliability Centered Maintenance), the primary focus should always be on minimizing risks rather than strictly cutting costs. By prioritizing risk reduction, significant cost savings can also be achieved in the process. - Vee
Hello Neil, it's crucial to ensure that the razor blade you purchase exceeds the minimum performance standards for optimal functionality. I struggle to comprehend the logic behind investing in a new product that barely meets the requirements, solely based on economic factors. Regards, Mike.
In the previous discussion about razor blades, it was highlighted that they can still be utilized efficiently even after surpassing the manufacturer's initial performance standards. Therefore, there is no need to label them as "failed" and replace them immediately after the first use. The same concept can be applied when understanding the relationship between Reliability Centered Maintenance (RCM) and economic considerations.
It is important to clarify that RCM is primarily focused on enhancing reliability rather than serving as a cost-cutting measure. By implementing RCM during the design phase of a project, optimal maintenance strategies can be determined, leading to a more effective Preventive Maintenance (PM) program. In instances where RCM is applied to existing facilities, it often results in a reduction of unnecessary PM tasks, thus lowering maintenance costs.
Conversely, if a facility has a limited PM program in place, RCM may recommend additional tasks to improve reliability and safety standards. While this may lead to a slight increase in costs, the benefits of preventing equipment failures and ensuring operational efficiency far outweigh the added expenses.
RCM has proven to be beneficial across various industries, including commercial nuclear environments, by streamlining PM tasks and identifying critical maintenance activities. Whether a facility has an excessive amount of maintenance tasks or lacks a comprehensive PM program, RCM can be tailored to enhance reliability and reduce overall costs.
In conclusion, the successful implementation of RCM results in a balanced and effective PM program that ensures the continued reliability of a facility. The economic advantages of RCM ultimately make it a valuable investment for any organization striving for operational excellence. For further insights, refer to Neil Bloom's book, "Reliability Centered Maintenance – Implementation Made Simple," published by McGraw-Hill.
I agree with Neil's point that it is crucial to separate Reliability Centered Maintenance (RCM) from its economic benefits. However, I believe that we often make the mistake of setting our performance standards too close to the minimum requirements, which can be tied back to the initial investment in the new plant. We may hesitate to invest in "over capacity" to avoid additional costs. This mindset can lead to trouble when the equipment's performance deteriorates naturally over time, leaving us with little room for error before functional failure occurs. Does this make sense to you? Mike.
Investors should familiarize themselves with this investment philosophy during the early stages of plant design. The distinction between function and functional failure is not always clear in all manufacturing sectors. However, this approach is becoming a common trend in some industries. J-