The Dangers of RCM Shortcuts

When people first begin to learn about Reliability Centered Maintenance and methodologies like RCM Blitz, they get excited about the potential results that can come from performing a RCM analysis and implementing the resulting tasks. Shortly after completing their RCM Training some begin to understand that good RCM takes leadership, structure and discipline, others begin to think of ways to shortcut the process.

One of the curses of being human is the burning desire to do everything faster. From the time we first learn to walk we have a desire to run, the minute the first automobiles hit the road someone had to make a faster one. In the world of manufacturing and maintenance speed can be a good thing but it can also be a bad thing. From the time Nowlan and Heap first designed and implemented RCM people have been in search of ways to make it faster and in most cases they do so by eliminating some of the key process steps. In many cases functions and functional failures are steps that are eliminated or partly eliminated. In each case the result is an incomplete RCM analysis and an incomplete maintenance strategy. The well meaning attempt to save time is usually driven by an inexperienced facilitator who does not have a full understanding of the consequences or an impatient manager with even less understanding. The list below outlines consequences of skipping functions and or functional failures when performing RCM.

Skipping Functions, listing only a main function, or skipping functional failures results in:

1.) Incomplete listing of failure modes (How can one expect a complete listing of failures without identifying each component?)

2.) Incomplete listing of hidden failures (If we don’t discuss each component and its intended function would we expect to discover failures that are not evident?)

3.) The inability to recognize when functional failure has occurred (Failure to recognize functional failure is key in beginning to recognize and understand potential failures and the P-F Curve)

4.) Improper applications of Preventive Maintenance and On-Condition Maintenance (Functions, Performance Standards and Functional Failures are all key components in understanding the use of on-condition maintenance and predictive technologies. Failure to identify these key components often results in preventive maintenance being applied where on-condition maintenance would be more applicable and effective)

5.) An incomplete and therefore less effective maintenance strategy (With all of the above being true how would one expect an effective maintenance strategy as a finished product)

A Modern Approach to Risk Management

Fasten your seat belts friends! For years I have been telling you all that RCM Blitz is the fastest and most efficient way to build a complete maintenance strategy for your critical assets.

What if I told you that RCM Blitz™ has been made even faster and more efficient AND it not only covered critical assets but we could develop a strategy for every piece of equipment at your plant?

The TEAM at Allied Reliability, Inc. has been working around the clock to perfect a tool that uses a three tiered approach to build a comprehensive maintenance strategy for every piece of equipment at your facility!

Starting with the Asset Health Matrix we quickly load your complete equipment hierarchy and perform a criticality ranking of your assets the information it then uploaded into the RCM Blitz™ software where within minutes a standardized EMP (Equipment Maintenance Plan) is developed for the engineered failure modes for all equipment regardless of criticality. For the top 10 to 20 percent of your critical assets we then perform a RCM Blitz™ analysis. With the intrinsic or engineered failure modes already covered your RCM Team will now focus exclusively on failure modes that result from the operating context of your assets. The last step of our process uses simulation models to optimize PdM task intervals based on the actual failure rate data following the implementation of your RCM Blitz™ tasks.

Having now utilized this approach and implementing the results at several facilities for three major manufacturing companies we are now ready to publicly offer this one of a kind tool to companies around the world!

Contact Allied Reliability to learn more about The Modern Approach to Risk Management.

RCM Blitz™ - Delivering Results

Someone once told me that you know you have made it in life when someone tries to copy the words you have written or a process you invented. Well, thanks to some folks in Malaysia, I guess I have officially made it. I'm also trying to feel good about the fact that someone has copied material that took me years to develop, and decided to offer it up to companies around the globe without consulting me first.

I guess I should feel honored! For some strange reason I don't.

For my loyal and successful customers over the past seven years I would like to say thank you! Allied Reliability, Inc. is thankful that customers like Whrilpool, Cargill, Invista, and Newmont Mining took the time to search and committed their people to research several methodologies looking for the best RCM Training and mentoring available around the world. Because these companies took the time and invested in RCM Blitz™ they now have successful RCM efforts with results that continue to provide return on the money they invested in RCM Facilitator Training.

For companies interested in RCM Training I would encourage you to read the article in the link and contact the good people at Allied Reliability, Inc.