Upon the completion of introduction to RCM training, attendees are able to:

• Describe RCM process
• Recognize the differences in RCM techniques
• Identify the importance of data and content prior to conducting any form of strategy operation
• Identifying and categorizing assets
• Understand the importance of FMECA in RCM
• Perform an RCM assessment
• Know how to make the strategy work
• Perform a task comparison
• Identify the work packaging should be done
• Recognize the techniques necessary for RCM implementation
• Understand a living program
• Understand the content of a RCM plan
• Comprehend Risk Based Inspection (RBI) within the asset management support tool

Introduction to RCM training is a 5-day course designed for:

• Maintenance personnel
• Plant managers
• Manufacturing engineers
• Rotating equipment engineers
• Maintenance supervisors
• Reliability engineers
• Planners, Schedulers
• Operations Managers
• Supervisors

Overview

• RCM definition
• The birth of RCM
• Background of RCM
• Understand the business context of RCM
• RCM standards
• What is criticality matrix?
• Which system to analyze?
• System boundaries identification
• Failure modes, failure causes, and failure effects
• Functions and functional failures
• Consequences
• Predictive and preventive tasks
• Default actions
• The importance of failure characteristics
• Run To Failure (RTF) maintenance
• When do design changes are required?
• How to propose maintenance to critical assets?
• The bathtub curve fallacy
• Cost-benefit considerations

RCM Customization and Requirements

• What is RCM customization?
• How to use RCM template data
• Identifying the required data for RCM
• How to become aware of the Asset Management Support Tool (AMST)

RCM project

• RCM project steps
• Risk Based Inspection (RBI)
• RBI variations
• RBI requirements

The RCM Process Basic Steps

• Preparation
• Analysis
• Task Selection
• Task Comparison
• Task Comparison Review
• Records

 RCM Components

• Reactive maintenance
• Preventive maintenance
• Predictive testing and inspection
• Proactive maintenance
• Acceptance testing

Methodology

• Weibull Distribution
• Problem Description and logic
• Mathematical Terms of Importance
• Mathematical modeling
• Monte Carlo simulation
• Reliability growth-Reparability models
• Exponential, binomial and Poisson models
• Kaplan-Meier Survivor model
• Risk Background

Practical Applications

• System selection
• System boundaries
• Required materials and documentation
• Plant personnel interviews
• FMECA
• System functions
• System functional failure
• Identification of equipment
• Identification of failure modes
• Identification of failure effects
• Criticality
• Maintenance criteria for non-critical components
• Reliability and Performance Data collection and processing
• Use of PSA to support RCM analysis
• Systems selection
• Identification of critical components
• The impact of the maintenance activity changes on Plant Risk
• The Increased Allowed Outage Time (AOT)
• PSA capability and insights
• Task selection
• Task selection guidance
• Maintenance templates
• Task selection hierarchy
• Task options
• Non critical components
• Task selection review
• Final phase of analysis
• Perform task comparison

Development and Deployment

• Management involvement
• Project management
• Analytical and software tools
• Databases
• Use of contractors
• Conditions monitoring program
• Skills and competences
• Project management skills
• Training
• Performance indicators
• Integration into O&M process
• Implementing recommendations
• Living RCM
• Factors for consideration in RCM implementation

Benefits

• Primary goals of RCM – Reliability
• Cost-benefits
• Contribution to long term Operation
• Soft
• Operations and Maintenance interaction
• Justification of maintenance tasks
• Feed back quality improved
• A culture of economic performance
• Questioning Attitude

Predictive Testing and Inspection Technologies

• Alerts and alarms
• Vibration monitoring and analysis
• Infrared Thermography
• Ultrasonic noise detection
• Lubricant and wear particle analysis
• Electrical condition monitoring
• Non-destructive testing
• Photography

Predictive Testing and Inspection Criteria

• Baselines
• Criteria by PT&I Technology

RCM Requirements During Facilities Acquisition

• Planning
• Predesign
• Design
• Construction
• Maintenance and operations

RCM Considerations During Facilities Operation

• RCM Program Data
• Maintenance feedback
• Maintenance and operations considerations

 RCM Contract Clauses

• General contract clauses
• Architect and engineering contracts
• Construction contracts
• Equipment procurement contracts
• Maintenance and operations contracts

Checklists for RCM Quality Assurance

• Planning
• Design
• Construction
• Equipment Procurement
• Maintenance and Operations

Key Performance Indicators (KPIs)

• General
• Purposes of KPIs
• Sample KPIs
• Trending Indicators
• Metric selection
• Benchmarking background
• Benchmark section
• Utilization of KPIs
• Planning and scheduling KPIs
• RCM KPIs

 Building Commissioning

• Building Commissioning Overview
• Types of Commissioning
• Commissioning Goals
• Commissioning and Sustainability
• The Commissioning Team
• The Commissioning Process

Maintainability

• Introduction
• Summary
• Maintainability, Reliability, and Availability (RCA)
• Theory of maintainability
• Background
• First principles of maintainability design
• Review for design maintainability considerations
• Replacement and modularity design requirements
• Fault detection and isolation design requirements