How do you integrate RCM with other reliability methods such as FMEA, RCA, and CBM?

What the LinkedIn bot wrote here is simply flawed. Conducting a Failure Mode Effects Analysis (FMEA) is a core part of the Reliability Centered Maintenance Process. When you address the 7 basic questions in the RCM process and document how an item can why, what causes the failure, and what are the consequences of the failure, you are conducting an FMEA. So, there is no need to 'integrate RCM with FMEA' as FMEA is an inherent part of RCM.

(1) Per Douglas Plucknette, FMEA was meant as a high level design tool. It views failure modes at a much higher level. The “pump fails” would be a FMEA failure mode. Where in RCM analysis there might be 10 or more significant failure modes that describe how components fail due to wear-and-tear and human error. Other points: (2) FMEA is a subset of RCM. (3) Corrective maintenance is an on-going function. Some of this equipment can have functional failures. This is when staff needs to capture the failure mode on a work order (WO). (4) RCM analysis should be performed on critical assets. The results of RCM & PMO should be stored in an RCM app within the CMMS for easy reference and update. A WO failure mode can be quickly compared to RCM app.

O FMEA bem elaborado traz uma gama de informações relevantes sobre os modos e efeitos das falhas potenciais de um equipamento. Isso dentro do RCM é enriquecedor pois dá a oportunidade de se buscar os tipos de manutenções e inspeções deverão ser utilizadas baseadas nos modos e efeitos de falhas, com a vantagem de já estar priorizado de acordo com o RPN. Em adicional, pode-se buscar a mitigação ou eliminação da probabilidade da falha observando se o maior risco da falha em questão se deve pela ocorrência, pela severidade ou pela falta de detecção.

Conducting a failure mode and effects analysis (FMEA) is part of the RCM process, you can't complete an RCM study without doing the FMEA.

La Metodología de Mantenimiento Centrado en Confiabilidad (RCM) según las Normas SAE JA1011 y 1012, tiene como fase central la realización de un Análisis de Modos de Fallas y sus Efectos (FMEA) simplificado, por lo que, RCM ya está integrado con el FMEA desde su propia concepción.

The criticality of a machine/equipment in Reliability Centered Maintenance is determined by the probability of failure, failure mode, and the failure consequences. The FMEA approach is used to identify machine criticality so that maintenance regime, inspection approach, spare parts availability, and backup (hot standby) can be planned properly.

They are all different tools to be used at different times for differing purposes and compliment each other when applied holistically

FMEA is an integral part of RCM. However, it should only focus relevant aspect of FMEA related to the desired function of an asset in its operating context. The key is to having a living FMEA to ensure that both RCM and Maintenance program are dynamic and up to date.

La integraciòn de ambas tecnicas, vinculadas a traves del riesgo que se genera a traves de los eventos de fallas analizados a traves del FMEA, genera ese plan de gestiòn de dichos riesgos que se describe en los nuevos planes de mantenimiento a fin de eliminar, mitigar, transferir o aceptar dichos riesgos que surgen por las fallas.

In my opinion here are some points to be explained about RCA: 1. Investigation: RCA involves a thorough investigation into the factors that led to a failure or problem. 2. Root Cause Determination: It aims to identify the fundamental reasons behind the failure, rather than just the symptoms. 3. Corrective Actions: Based on the findings, RCA recommends specific corrective actions to prevent the recurrence of similar issues. 4. Reactive and Proactive Use: It can be used reactively to learn from past failures or proactively to anticipate and prevent potential future failures.

RCM is a living program, so always failure events happen can be conducted RCA and become a lesson learned and opportunities to identify gaps or failure modes not addressed in the last RCM study. All new failure modes discovered should be addressed and incorporated with new tasks (If feasible) in the RCM study.

The process of documenting, monitoring, and looking into failures and incidents to find the underlying causes, implement remedial measures, assess incident patterns, and share knowledge gained all could be based on appropriate root cause analysis studies outcomes. RCA of accidents, major events & failure are considering as great chance to review, Identify gaps, improvement, assess and evaluate control measures, address human factors and , etc., RCA outcomes are the metric of RCM effectiveness. The incident investigations could be considered as a chance to revaluate & the assess as well as redefine the outcomes of RCM study based on real scenarios. we target 5% of reported events to be further analyized through RCA in quarterly basis.

La propia Norma SAE JA1012 que da marco al RCM, recomienda la integración del Análisis de Causa Raíz y plantea que el Análisis de Modos de Fallas que se realiza dentro del proceso de RCM, se puede realizar a distintos niveles de profundidad. A mayor nivel de profundidad en el análisis, mayor eficacia se podrá lograr en el Plan de Mantenimiento elaborado.

RCM can be integrated with other reliability methods to improve the reliability of systems and assets, reduce costs, and increase safety. FMEA can be used to identify potential failure modes and their effects before implementation, RCA can be used to investigate the root cause of failures that do occur, and CBM can be used to monitor the condition of assets and schedule maintenance tasks accordingly.

Una vez surgida la falla y valorado su impacto, se emplea el RCA para determinar la causa raiz de la falla. Esta causa(s) permite establecer una serie de acciones que pueden comprender desde un cambio en diseño, en operacion, entrenamiento y capacitaciòn, hasta la inclusiòn de una o varias actividades en el plan que eviten la ocurrencia de dicha falla.

O RCA é fundamental para se girar o PDCA dentro do RCM. Uma vez que se define os planos de manutenção adequados para os modos de falha listados no FMEA, deve-se aplicar RCA de forma robusta para encontrar a causa raiz de cada falha encontrada e realimentar os planos de manutenção para que se evite a recorrência dessa falha. As técnicas que mais recomendo usar são Ishikawa + 5Whys; Árvore de Falhas e para casos mais crônicos / críticos o método Apollo.

To seamlessly integrate RCA (Root Cause Analysis) with RCM (Reliability Centered Maintenance), start by aligning the objectives of both processes. Ensure that the findings from RCA contribute directly to refining the maintenance strategies identified in RCM. Remember, the key is synergy – making sure that the knowledge gained from identifying root causes is seamlessly woven into the fabric of your Reliability Centered Maintenance strategy.

Conduct RCA on Failures: When failures occur, perform a Root Cause Analysis to identify underlying causes. This analysis should feed back into the RCM process to refine maintenance strategies and prevent recurrence. Continuous Improvement: Use findings from RCA to update the RCM framework, ensuring that maintenance strategies evolve based on actual performance data and lessons learned.

CBM traz mais assertividade para os resultados de manutenção, pois só evidencia a necessidade de se parar o equipamento para intervenção mediante uma inspeção sensitiva ou através de sensores de vibração, temperatura e outros dados que podem ser coletados. Essa técnica reduz a quantidade de planos de manutenção baseado em tempo, que são mais custosos, recorrentes e que podem inserir uma falha no equipamento.

Las Normas que dan marco al RCM, la SAE JA1011 y JA 1012, priorizan la aplicación del Monitoreo de Condición, por consiguiente, el CBM está integrado a la naturaleza del RCM.

Integrate Condition Monitoring Data: Use CBM techniques to monitor equipment conditions in real-time. The data collected can enhance the RCM analysis by providing insights into the actual health and performance of assets. Dynamic Maintenance Strategies: Allow RCM to incorporate CBM data for dynamic scheduling of maintenance tasks based on the actual condition of equipment rather than solely on time-based intervals.

CBM permite controlar esas variables criticas en los equipos o facilidades, para tomar acciones proactivas de mantenimiento evitando la ocurrencia de la falla. Este monitoreo debe estar contemplado en los planes de mantenimiento, como un producto generado a traves del RCM.

CBM is a crucial task that can be incorporated into the RCM journey. Over the years, CBM has, in most cases, demonstrated the most feasible and cost-effective strategy for RCM deployment. In recent years with the advancement of IoT technologies, CBM has shown an important tool to maintain reliability. RCM is a living program, therefore the strategies should be reviewed continually to identify opportunities to replace PM tasks with CBM tasks (where possible and feasible), or replacement in the way that these tasks are conducted, for example, changing offline routes to online monitoring with add of new technologies like IoT devices and AI technologies.

Integrate Condition Monitoring Data: Use CBM techniques to monitor equipment conditions in real-time. The data collected can enhance the RCM analysis by providing insights into the actual health and performance of assets. Dynamic Maintenance Strategies: Allow RCM to incorporate CBM data for dynamic scheduling of maintenance tasks based on the actual condition of equipment rather than solely on time-based intervals.

FMEA, CBM, RCA and other data are used as inputs into the RCM process. Reliability-Centered Maintenance, a system developed by Nowlan and Heap of United Airlines for the US Military in 1978, is a process for developing maintenance, engineering or modification to a component or system in order to meet it's design. FMEA, in particular, is a direct step in the process in which you define failure, determine the modes and effects on the system and then assess methods to detect or avoid the failures. The result is a system that is meant to ensure the right maintenance on the right systems at the right time for the right reasons.

In my experience RCM and the other three and four letter acronyms are little more than a paperwork exercise. Reliability is proactive hard work that is proper lubrication, contamination control, and proper installation. I agree that RCM was first stolen by: Matteson, Heap, and Nowlan. They were tasked to study aircraft maintenance and reliability requirements for United Airlines, and took the knowledge of the qualified others and capitalized. Matteson severed his ties with the others because of the dishonest and misleading perception that they developed anything. They copied what others knew and packaged it to unknowing folks that were fooled into thinking it was new. Stop trying to copy your way to a competitive advantage.

Antes de pensar em implementar o RCM, tenha certeza do nível de maturidade da equipe, da estratégia atual e da disposição da empresa para esse projeto, pois RCM é uma jornada que trará excelentes frutos, porém é um tanto complexo para não se estar preparado antes de iniciar.

First, make sure you clearly define each of the elements. There is overlap and unless you have accepted the definitions from a single (accredited body). Most likely each vendor will have something mostly the same but slightly different. From an organizational standpoint I believe they all are somewhat sequential. Choice what adds value. RCM and FMEA, you do first to determine, what is going to break and how. Setting up your CBM (&PM) activities. CBM is how you watch and monitor your equipment. RCA is done, after some type of negative event to determine what went wrong. Take corrective actions and run them back through your RCM/FMEA filter to possibly make changes to your CDM.

If the RCM you are referring to is Reliablity Centered Maintenance, the next 3 fall under that. My personal opinion is that some try to reinvent the wheel for whatever reason with new acronyms, catch phrases, etc. Tried and true practices have been around for decades. The problem is they don't get executed. A lot of the work needed is not sexy, not fun, no shiny tool or technology. You just have to bear down and do it. My 2 cents.

RCM é uma jornada, e faltou mencionar que com IA, cloud e sensoriamento de última geração, podemos evoluir para a manutenção prescritiva e monitorada à distância, trazendo mais assertividade e eficiência.

To do RCM be successful to become strategy beside of the synergy others tools if RCM,like FMEA,RCA and CBM the quality of data,readiness of people and organization and performance tools such as KPI's and matric RACI should be executed with consitance and commit and should have feedback for evaluation and improvement and also continuous improvement.