RCM Assessment- Blog Series Part 5
In continuation of my ASPM blog series, I will continue to focus on the 3rd step in which I will take up RCM assessment.
In my previous FMEA blog, I did FMEA assessment on “Dewatering Pump” and the RPN for the equipment was 1600 which indicated that I should proceed with the RCM assessment for the equipment.
Highlights of RCM assessment –
- RCM assessment is a complex process in which all the unknown of the asset is identified, hence it requires a team who are well versed with the asset and its current maintenance strategy.
- The very first step of RCM is to define its operating context and required functions under it. The logical starting point is to understand what is being demanded from the asset.
- Function – The RCM team must describe functions – All primary and secondary functions of the asset is been identified.
- Functional Failure – A functional failure is defined as “a state in which a physical asset or system is unable to perform a specific function to a desired level of performance”. It is instrumental to have a perfect understanding of the asset functions and the desired performance level to determine functional failures. The asset may not be able to fulfill a function at all or that it may perform it at a lower than the desired performance level.
- Failure Mode – A failure mode is a single event, which causes a functional failure to occur and each failure mode usually has one or more causes. So, we need to brainstorm on all possible events causing assets to impair their ability to perform each specific function to the desired levels of performance.
- Failure Cause – All failure modes reasonably likely to cause each functional failure shall be identified. The method used to decide what constitutes a “reasonably likely to occur” failure mode shall be acceptable to the owner or user of the asset. Usually consensus is used to decide which failure modes to analyze and which ones to discard. Human and design errors causing failure event must be included in the failure mode list unless they are being addressed by other analysis methods.
- Failure Effect – Failure effects quantify the “damage” each failure event may cause to the plant or the organization. It is recommended to describe “what happens when the failure mode occurs”. Failure effects help determining the extent to which each failure mode is relevant .
- Consequence evaluation – Failure effects are classified into categories based on evidence of failure, impact on safety, the environment, operational capability, and cost. We should be able to decide which of the four categories apply to each failure mode effects. Hidden and evident failure modes must be clearly separated. Like every step within the RCM process, failure consequence determination is critical. Maintenance strategies are carefully selected for every critical failure effect based on a decisional procedure using the outcome of the consequence evaluation.
There are different flavors of RCM assessment-
- Few organizations, do RCM along with consequence evaluation at the effect level
- Few other organizations, combine FM and cause together.
- While few prefer to do risk assessment at effect or FM level during RCM – (Future scope)
To keep the example simple, I will do the RCM assessment without combining FM and cause and do a consequence evaluation at the effect level. Advanced checklist template is used to create the consequence evaluation flow.
Creating a RCM template is different from other template creation where you would add impact, dimension etc. RCM template creation is a simpler process where you add the advanced checklist template details to create the consequence evaluation and other mandatory details.
Along with below information, in RCM template you will maintain the roles and assignment details also. The usage of roles and assignment is same like other templates. With role setup, you can define which roles are required as mandatory or optional in the RCM assessment. Assignment tab ensures that company admin assigns equipment template and all equipment from the equipment template should use the respective RCM template for RCM assessment. This information is available in the pending assessment highlight card in the equipment page.
To trigger a RCM assessment, it is possible from four places similar to other assessment. For RCM, I will trigger it from RCM application itself
- Navigate to RCM assessment tile in the FLP. It will display the list of all RCM assessment done in the system. Click on “New” and maintain the details. I will use the RCM template which was created earlier. Once the RCM assessment is created, you can maintain the scope description and roles for the assessment.
- Since I created the RCM from the RCM tile directly, hence no asset is assigned. I will explicitly assign the “Dewatering Pump” in the RCM assessment.
- Each asset can be used in a different context, for example pump getting used in cold region and in desert region will have different set of issues and resolution. Hence it is necessary to understand the operating context in a RCM assessment. From the “Context Information” you can maintain the operational context. Based on the operational context the functions and functional failures are determined.
- Along with operational context, all the maintenance plans associated with this equipment in ERP is also available in the context information. Knowing how the asset is getting maintained currently, will help me as a reliability engineer to decide on the failure modes and its effect. Also I can created new set of recommendation based on the maintenance plan in the ERP.
- Based on the context information available I have assigned the below set of data in the RCM assessment. Same like FMEA assessment, RCM assessment is also to find the unknown details of the asset and you can assign functions, functional failures, failure modes and effects. If required you can also create new data during the RCM assessment.
- Once the entire data is assigned, we will proceed with consequence evaluation of the effect. Each node provides details on clicking on the “i” button.
- In the details part, you get various options like editing the function, functional failure, failure mode, effect’s short and long description. You can also view the hierarchy of the details.
- The consequence evaluation is done using the advanced checklist template which was assigned in the RCM template.The selected answers is also shown in the simulate button which helps to understand the flow of the answers in the consequence evaluation
- The entire process of RCM is completed when the reliability engineer creates a set of recommendation. I will provide details of recommendation in my next blog series.
- All the RCM assessment created for the asset is available in equipment page.
I will publish the RCM assessment after I have created the set of recommendation, hence for now I have kept the RCM assessment unpublished.
In my next blog series I will cover recommendation creation which is possible from both FMEA and RCM assessment.
Series 1: Brief Overview of ASPM and Master data setup
Series 2: Risk and Criticality (RC)
Series 3: Failure Mode Effect Analysis (FMEA)
Series 4: Checklist Assessment
Series 5: Reliability Centered Maintenance (RCM)
Series 7: Preventive Maintenance Review (PMR)
Thanks for the detailed document. We have all the Functions, Function Failure, Failure Modes, and Effects data and RCM 2.0 assessment is also performed on some equipment. I would like to know that how do we migrate the RCM assessments that are already done in the legacy system? Is there any upload template available that can be used to create these master data?
You can use public API to build a custom application to migrate the data from legacy system to ASPM application.
Just wanted to check that what is the role of 'Failure Event' which is mandatory while creating Function Failures. There are three options available: 1) Alert, 2) Service Ticket & 3) Notification
Could you please tell me that How do I test this functionality?
The intent of that field is to trigger next action when the functional failure happens. For example, lift had a functional failure, it should create an alert or notification etc. Currently, the automatic alert/service ticket/notification creation is not enabled.
Thanks Rupali for your prompt response. I understand that the automatic feature is not available as of now, then how is this supposed to work?
And where else do we use 'Function Failure' apart from the assessments (FMEA or RCM)? So, assuming that even if the automatic trigger is present, then what is the action that will trigger this because assessments are done in advance where we use these Functional Failure. I mean we are not inputting this 'Functional Failure' anywhere in case if the failure happens.
Yes, currently it is consumed in RCM. Further integration not available yet and can be addressed later.
Good day to you! I wanted to clarify one functionality with you in ASPM. When I perform RCM assessment and assign similar equipment in the assessment (as shown in the attachment), I am able to perform the assessment on 1 equipment at a time. How do I copy the assessment or the steps performed (Functions, FF, FM and Effects Tree Structure) from one equipment to another if they are the same as the assessment performed on one Equipment will be applicable to all others. Kindly help to advise how this requirement can be met?
I don't see any copy functionality within an assessment or to copy a complete assessment from the list
Currently you cannot copy the information from one equipment to another equipment. If the feature is planned in future, roadmap will be updated.
Thanks & Regards,
Thanks for your response. Would it be possible for you to recommend any workaround for this case where we have to perform an assessment for the same type of Equipment?
You can probably use the API to read from one equipment data and assign to another equipment.
From UI side, unfortunately we dont have a easier solution currently
Thanks for the recommendation. Even I thought of this but if we have complex hierarchy of Function, FF, FM and Effects and consequence evaluation on top of that, then isn't it a very tedious task to do this through APIs as well. Because APIs only fetch one level detail of this complex hierarchy at a time. And even the consequence evaluation for one combination of Function, Functional Failure, Failure Modes and Effects at a time. Then pushing it for another equipment will take same number of steps. Correct me if I am missing something.
Yes, it is going to involve many API calls. However I dont have any other solution currently.