RCM Study Content

To verify the quality of the RCM content FM-by-FM can be labor intensive.
It is recommended to use key figures and parameters, to filter out deviations using statistical data.

For example: looking at the filters in the analyses screen, a direct and simple insight in the RCM study content can be gained from the data selected:

Above: opening the Analyses grid filter enables insight in the amount of particular content, like for example:

• High criticalities
• High residual risks
• Priorities
• MEI classes
• (In-) Completeness
• Approval States
• High/ Low ETBC/ETBF ratios
• High/ Low ETBF ranges
• High/ Low task count

For more depth of data the query E03: RCM Analyses Overview Cr-RR-Appr can be used.

A recomended quality check flow is:

Above: Check the 'Completeness of the Analyses'.

Above: Check that the Tasks address the FM's.

Above: Check that the Tasks are appropriate and complete. Are restoration Tasks involved?

Above: Using Analyses or Task export and an Excel pivot table, enables the visualization of the Object type - FM - Task type and Task in a structured way, to assess if the Tasks are appropriate.

Above: Check that the Task frequencies / intervals align with the PF curve and the scenario.

Above: Check that the Criticality and the Residual Risk are OK.

Above: Check that the MEI is ok, verify if MEI Thresholds are set, resonably.

Above: Check that the Tasks are complete and handover for execution can be done well. Are realistic costs involved?

RCM Quality checklist.

Below a list of checks are provided that can be used in a RCM quality check:
As base data set, an Excel-export of the Analyses grid or the tasks grid can be used.

1. Check time based Tasks applied on Non-Age related Failure Modes.

2. Check all Criticalities of H and E level on scenario.

3. Check Failure Modes ranking high on HSE (fire, explosion) on economics (repair).

4. Check all MEI value’s between 0 and 1.5.

5. Check all annual factors >500.

6. Check that highest Task frequency of a Failure Mode has an interval not above the ETBF.

7. Check Failure Modes with very short ETBF (< 0.4 years).

8. Check Failure Modes with very long ETBC (>50 years).

9. Check number of task execution’s till ETBF: ETBF x Annual Factor; especially for N and L criticalities.

10. Check man-hours to do the Task – per year: task time x annual factor. Check man-years for all Tasks.

11. Verify that Time Based Tasks are actual ‘activities’ and time based monitoring Tasks are flagged as Condition Monitoring.

12. Verify that Condition Monitoring Tasks are accompanied by Condition Based Tasks.

13. Verify that Condition Based Tasks are not ‘stand alone’ and linked to a Condition Monitoring Task or Time Based Task.

14. Verify that Condition Monitoring Tasks are accompanied by a statement at which monitoring value (what) action to take.

15. Ensure there are no Tasks with an empty Work Instruction.

16. Ensure no dummy Equipment numbers, Equipment types and Equipment names are used.

17. Ensure there are no (real) Tasks with a task POC = 0.

18. Ensure there are no (real) Tasks with a Task frequency = 0, or blank WC, or blank Task Type.

19. Ensure there is a consistent marking of Tasks that need execution during Turn-arounds.

20. Ensure all Frequencies that require a manual annual factor to be entered are supplied with Annual Factors, and match the standard values.

Merged tasks in RCM.

Tasks can be merged in case they are similar. IMS recognizes similar Tasks and indicates that they are potential candidates for merging in the MEC board, see example:

In this process, there is one 'main' Task where the merged Tasks are merged to, and the (POC) costs of the 'main' Task are included in the MEI calculation of the FM.
The costs on the merged Tasks are excluded from the MEI calculations.

Note that this can have some typical side effects:

1. If there is a single Task on various FMs, and this Task is merged, the costs of the merged Tasks are not included in the MEI calulations and the Total Ann POC on these FMs becomes 0.
   A zero Total Ann POC leads to an MEI of zero, typically meaning the RCM Analysis does NOT rank.

2. If Tasks on various FMs are merged, it might be needed to indicate on the 'main' Task that it is applicable to various FMs, probably with various checks involved in this Task.

3. As the costs of merged Tasks are only calculated for the 'main' Task, it can be that the MEI where the 'main' Task resides in, has a higher Total Ann POC and a lower MEI.

In the above example with 5 FM's, with each having one Task, there are three Tasks merged and the MEI of the three FM's involved became 0. It is recommended to to put the 'main' Task on the highest criticality FM and the merged Tasks on the lower criticality FM's.