Once you've checked the size of the study (see RCM Study Size), the next step is to look at the quality of the RCM content itself. Reviewing this failure-mode by failure-mode can be labor intensive, so it helps to use key figures and parameters to filter out deviations using statistical data.
For example, opening the filters in the Analyses screen gives you a direct and simple insight in the RCM study content, based on the data you selected:
Opening the Analysis grid filter gives you insight into the amount of particular content, such as:
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, you can use the query E03: RCM Analyses Overview.
Recommended Quality Check Flow
You can follow this flow to check the quality of an RCM study:
Start by checking the completeness of the analyses.
Check that the Tasks address the failure modes.
Check that the Tasks are appropriate and complete. Are restoration Tasks involved?
Using an Analyses or Task export and an Excel pivot table, you can visualize the Object type, failure mode, Task type, and Task in a structured way, to assess whether the Tasks are appropriate.
Check that the Task frequencies and intervals align with the PF curve and the scenario.
Check that the Criticality and the Residual Risk are OK.
Check that the MEI is OK and verify whether MEI thresholds are set reasonably.
Finally, check that the Tasks are complete and can be handed over for execution well. Are realistic costs involved?
RCM Quality Checklist
You can use the checks below as an RCM quality checklist. As base data set, use an Excel export of the Analysis grid or the Tasks grid.
Check time-based Tasks applied on non-age-related Failure Modes.
Check all Criticalities of H and E level on scenario.
Check Failure Modes ranking high on HSE (fire, explosion) on economics (repair).
Check all MEI values between 0 and 1.5.
Check all annual factors greater than 500.
Check that the highest Task frequency of a Failure Mode has an interval not above the ETBF.
Check Failure Modes with very short ETBF (under 0.4 years).
Check Failure Modes with very long ETBC (over 50 years).
Check the number of task executions till ETBF (ETBF x Annual Factor); especially for N and L criticalities.
Check man-hours to do the Task per year (task time x annual factor), and check man-years for all Tasks.
Also verify the following about Tasks and Condition Monitoring:
Verify that time-based Tasks are actual “activities” and that time-based monitoring Tasks are flagged as Condition Monitoring.
Verify that Condition Monitoring Tasks are accompanied by Condition Based Tasks.
Verify that Condition Based Tasks are not ”stand-alone” and are linked to a Condition Monitoring Task or Time-Based Task.
Verify that Condition Monitoring Tasks are accompanied by a statement of what action to take at which monitoring value.
Ensure there are no Tasks with an empty Work Instruction.
Ensure no dummy Equipment numbers, Equipment types, and Equipment names are used.
Ensure there are no (real) Tasks with a task POC of 0.
Ensure there are no (real) Tasks with a Task frequency of0, or a blank WC, or a blank Task Type.
Ensure there is a consistent marking of Tasks that need execution during turnarounds.
Ensure all frequencies that require a manual annual factor to be entered are supplied with Annual Factors that match the standard values.
Merged Tasks in RCM
You can merge Tasks when they're similar. IMS recognizes similar Tasks and flags them as potential candidates for merging in the MEC board, as shown here:
In this process, there is one “main” Task that the others are merged into, 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:
If a single Task on various failure modes is merged, the costs of the merged Tasks are not included in the MEI calculations, and the Total annual POC on those failure modes becomes 0. A zero total annual POC leads to an MEI of zero, which typically means the RCM Analysis does NOT rank.
If Tasks on various failure modes are merged, you may need to indicate on the main Task that it applies to various failure modes, probably with various checks involved in this Task.
Because the costs of merged Tasks are only calculated for the main Task, the failure mode where the main Task resides can end up with a higher Total Ann POC and a lower MEI.
In the example above, with five failure modes each having one Task, three Tasks are merged and the MEI of the three failure modes involved becomes 0. It's recommended to put the main Task on the highest-criticality failure mode and the merged Tasks on the lower-criticality ones.