What is RCM and how it can be implemented on large scale factory?

Thanks for the question on which I am gaining idea  on perusal of answers from experts.

Reliability Centered Maintenance (RCM) is a process to ensure that assets continue to do what their users require in their present operating context

RCM as mentioned by every one is the right use of resources at the right time for the purpose of maintain the resources by performing maintenance in a systematic method and process there by the reliability of the asset meets assumable standards (when taken in terms of turnaround time, preventive maintenance time/duration. breakdown maintenance time/duration, productivity duration, optimized resource allocation including manpower, parts and logistic, running hours, rate of failure, duration of maintenance performed). Thus in short it would give the most consistent performance.

RCM involves greater level of Project Management life cycle with industry/product life cycle requiring greater level of initiation preparation, detailed level of planning for smoother execution phase and closing out the part of the activity. Even though the maintenance activity is cyclic it can be decomposed to a level of close out. So the initiation requires decomposing the entire plant/machinery or process/section and then identify the failure modes and then evaluate the level of reliability of the components leading to parts that forms the sections, by doing the failure mode study, running cycle study, maintenance cycle study, activity resource study etc. In a way by decomposing the complex plant to smaller unit it makes it easy for detailing out and helps the later stage of planning easy. The initiation stage looks on the cost and advantages of the RCM process implementation benefit. In the planning stage each sections and level of maintenance and cost is accessed and then chosen out for RCM plan or for breakdown maintenance (this depends on the type of plant, the working/production durations like8 hrs. a day or24/7 working, the effect of the maintenance on production. Then the planning is done by using a Gantt chart or some project management software or simply the CMMS and RCM software’s or if it’s a simple type then using excel to formulate the planning of methods, duration, resource allocation, cost etc. Then the executing the RCM, section wise or based on the parameters of maintenance, cost and resource. In a complex environment it requires the coordination of production, maintenance team and specialist teams like reliability engineers, process engineers and operations/management.

The best way to implement the RCM is by breaking down the plant in levels like, take the plant from one end of the process usually the input and then consider the process then look on to the parts in those section and then classify the parts as mechanical, electrical, electronics, chemical, mechatronics etc then look on the components in the parts and see the failure mode and its impact and assign the rating and then give overall rating to the components and level of impact of the failure by time taken for maintenance and the frequency of failure. Then assess the reason for the failure, probably give solution for it by redesign, change in specification, change parts etc. Then provide the maintenance procedure or pre-maintenance activity/procedure and method, the resources required.

RCM is an effective concept in terms of theory, but in practice it’s a complex task to attain it and as the plant size and complexity and no of components increases, the RCM activity and triggers increases. RCM is effective by having dedicated work time or team assigned and by dividing the level of study to a considerable level or by considering the RCM initiation stages progressively, which requires time, resource, cost and detailing. Thus we have heads, principle section head, in-charges, maintenance teams, specialist engineers etc. made to handle the complexity. To be practical one person handling RCM in a complex environment is like looking for fresh water in the desert alone.

R C M on large factory need split ( chopping ) sections & each section its R C M  ( insurance) from onther section different .

Example : section  1  2000$

section2  2500$

section32800$ 

section4  2950 $

section53200$

It is important to what is important, what is more important and what is the most important! Reliability of system should be reached!....

RCM  reliability centered management is to ensure that the right maintenance activity is performed at the right time with the right people, and that the equipment is operated in a way that maximizes its opportunity to achieve a reliability level that is consistent with the safety, environmental, operational, and profit goals 

in order to apply it on large scale , you have to prioritize your plant section then define  RF targets per each area depending on the products flow and to the importance and assign to each dept. head and ensure 

Thanks for each contributions,

But Do you have some documents that can be used to implement this theory on small factory ?or there is some conditions before applying it? please give me your opinion

in order to apply it on large scale , you have to prioritize your plant section then define  RF targets per each area depending on the products flow and to the importance and assign to each dept. head and ensure

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