To demonstrate how the IMS-RCM tool delivers value, this article provides examples of its functionality in line with the relevant RCM business process aspects. It is assumed that engineers using the IMS-RCM tool are already familiar with the RCM business process. Therefore, the IMS-RCM manuals do not include a detailed description of the process itself.
Instead, this article provides a summarized overview of the RCM business process to illustrate how tool functionality supports each stage.
The RCM business process aims to achieve the desired production output through the most effective maintenance approach for physical assets. Continuous learning and improvement are enabled by applying the recurring sequence of the Deming “Plan-Do-Check-Act” (PDCA) cycle.
Plan
Based on a company’s operational performance, “areas for improvement” can be identified to drive reliability improvement initiatives, including RCM analyses. Typical areas of interest are low operational plant availability and high maintenance efforts. The Reliability Manager leads the identification and prioritization of these areas.
RCM studies are planned with particular improvement objectives in mind, typically starting with a multi-year outlook that is translated into annual plans for RCM studies. Finally, individual RCM studies are then conducted for specific plants or units.
Do
RCM studies are prepared and executed by the RCM facilitator, who is expected to be the key user of the IMS-RCM tool. Preparation is typically documented in a Terms of Reference (ToR), which defines the RCM study scope and estimates the required information and resources.
Example ToR documents include:
The execution of an RCM study typically involves a Failure Modes and Effects Analysis (FMEA) structured around the seven RCM questions.
This approach identifies the most cost-effective actions to reduce the probability and impact of equipment failure. RCM seeks the optimal mix of condition-based or predictive actions, with some time-based maintenance and some run-to-failure strategies.
The applied RCM methodology is a “streamlined” approach focusing on dominant (recurring) failure modes.
Evaluation of Maintenance Strategies
The most cost-effective actions identified by the RCM approach are evaluated in the following ways.
MEI (Maintenance Efficiency Indicator)
By comparing the “no maintenance” scenario with the “do maintenance” scenario, one can determine whether the suggested maintenance strategy is cost efficient. MEI calculations compare risk reduction against maintenance cost, determined in monetary terms. When risk reduction is larger than maintenance cost, MEI is greater 1 – indicating the maintenance strategy is cost effective.
What – If Scenarios
Alternative strategies are analyzed by creating and modifying scenarios (clones) to identify the most effective approach. These comparisons support continuous improvement and justify the recommended maintenance strategy.
Check
Once an RCM study is completed, its effectiveness is evaluated using the following metrics.
Number of analyses and failure modes assessed.
Criticality levels and achieved risk reduction.
Distribution of failure modes by equipment type.
Types and numbers of maintenance tasks (condition-based, time-based, run-to-failure).
Handover of the tasks for execution.
Time required to complete the RCM study.
The IMS-RCM tool provides extensive functionality to provide these insights, both for final reporting and for monitoring progress during the RCM study.
The outcome of the “Check” phase is typically an end report confirming whether the RCM study achieved the objectives defined in the ToR and approving the results to be implemented. Implementation involves scheduling and executing the identified maintenance tasks.
A second aspect of the “Check” phase focuses on long-term performance improvement. Over time, operational performance should improve as a result of implemented reliability initiatives. We refer to this as the “living program”. The IMS-RCM tool supports this through periodic review of operational and maintenance data.
Act
Insights from the “Check” phase are used to refine future RCM studies. This may include adjustments to:
Equipment selection.
Data requirements.
The sequence in which equipment is addressed.
Resource allocation.
Study duration.
Additionally, the impact of RCM studies on operational performance is reviewed to confirm whether identified improvement areas have resulted in measurable reliability improvements.
Roles and Responsibilities
Reliability Manager
The Reliability Manager is responsible for planning and overseeing RCM studies through to implementation and approval of results. This role requires a strong understanding of RCM principles (at least RCM Knowledge competency).
RCM Facilitator
The RCM Facilitator leads the preparation and execution of RCM studies, including individual RCM studies or “Living program” RCM reviews. This role requires strong facilitation and technical RCM expertise (RCM skilled facilitator competency).
Competency Levels
The following competency levels for RCM and facilitation are outlined for the Awareness, Knowledge, and Skilled tiers relevant to the implementation of IMS-RCM.
RCM Awareness
Understands basic RCM principles.
Recognizes RCM relevance to the business.
Can describe key RCM elements.
Identifies where RCM competencies apply to their role.
RCM Knowledge (in addition to Awareness)
Interprets and evaluates expert input.
Uses RCM terminology correctly.
Engages in informed discussions on RCM.
Assesses feasibility of RCM proposals.
Performs selected RCM activities with guidance.
RCM Skilled (in addition to Knowledge)
Independently executes RCM processes to required standards.
Explains and applies RCM process steps.
Translates guidelines and standards into practical actions.
Solves common technical and operational issues.
Guides and advises others in operational and technical aspects of the RCM work process.
This competency level is required for a site RCM process focal point.
RCM Skilled Facilitator (in addition to Skilled)
Prepares, executes, and finalizes RCM workshops effectively.
Facilitates participant engagement efficiently.
Translates technical input into structured RCM analyses.
Evaluates RCM outputs and produces final reports with clear recommendations.
RCM Methodology References
For further details on RCM, refer to the following key documents.
RRM S-RCM Manual, Shell Global Sol. V2 OG 04-30260
RCM II book by John Moubray; ISBN 9780831131463
SAE JA1011, Evaluation criteria for Reliability Centered Maintenance (RCM) Process.
SAE JA1012, A guide to the Reliability Centered Maintenance (RCM) Standard.
ISO 60300-3-11, Application guide Reliability centred maintenance
ISO 14224; Collection and Exchange of reliability and maintenance data for equipment;
IEC 60812; Analysis techniques for system reliability – Procedure for failure mode and effects analysis (FMEA)