RCM Basics - 7 Questions

At its core, RCM is a process guided by a series of key questions that systematically evaluate how an asset operates, how it can fail, and what can be done to prevent or mitigate those failures.

The following seven questions outline the essential steps in the RCM process, from understanding functional requirements and failure mechanisms to establishing effective maintenance programs tailored to the specific needs and characteristics of an organization’s assets.

1. What are the functions and associated performance standards of the asset?

The first question in RCM focuses on understanding the functions of the asset and the performance standards associated with these functions. This involves defining what the asset is supposed to do, and the criteria for determining whether it is functioning properly.

2. In what ways can it fail to fulfill its functions?

The second question seeks to identify the various ways the asset could fail to fulfill its functions. These could include complete failure, partial failure, or degraded performance.

3. What causes each functional failure?

It is crucial to identify the cause of each functional failure. When a piece of equipment malfunctions, we refer to it as a failure mode. Failure modes can be caused by wear and tear, improper use, environmental conditions, or design flaws.

4. What happens when each failure occurs?

Question four delves into the progression of failures, exploring how each failure initiates, progresses, and culminates in a failed state. This is the so-called failure scenario. Understanding the consequences of each failure helps in prioritizing maintenance tasks.

5. In what way does the failure matter?

The fifth question focuses on determining the criticality of failures by assessing the consequences when a failure occurs. If the failure matters, we should do maintenance to reduce the risk. More risk justifies more maintenance. In case the risk is low, we might not do scheduled maintenance.

6. What can be done to predict or prevent each failure?

This question focuses on identifying maintenance tasks that can be implemented to either predict or prevent potential failures in equipment. With this question we delve into the proactive aspect of maintenance, aiming to anticipate and mitigate failures before they occur.

7. What should be done if a suitable proactive task cannot be found?

The final question focuses on actions when a suitable proactive task is not found, stressing task effectiveness in risk reduction and economic feasibility. If risk reduction and economic benefit are sufficient, the proactive tasks are suitable. If not, a reactive approach might be necessary. This could involve running the asset to failure and then repairing or replacing it.

Components of RCM and their relationships