Reliability-Centered Maintenance Handbook

1 S9081-AB-GIB-O1/MIAINTR eliability-CenteredMaintenanceHandbookII DTFC' SEP 0 71988nPublished by Direction of Commander, Naval Sea Systems Command88 9 6 252 Revised: October PraA5S:PICATIOTI OF T-HIS IA6 EREPORT DOCUMENTATION PAGE)a..U-iUII I SZCURITY CLAFSSIFICATION T b. RESrRI01IL MAAP. ECUAITRC-ASTW91N AUTHORITY 3. DISFRIBUTION /AVAILABILITY OF Rl:I r1Zb. DECLASS i~CATION/DOW',NGRADIFJC SCHEDULE Public release4 PEPim-ORM)NG, ORGANIZATION REPORT NUMBER(S) S. MONITORING ORGANIZATION iIEPoRr NUMBER(S)S9O81-AB-GIB-Ol0/tiaint S9O81-AB-GIB-010/MAINT6a. NAMAE OF PERFORMING ORGANIZATION 6ib OFFICE SYMBOL 7a.

2 NAME OF MONITORING ORTGANIZATIONJ(if applicable)Naval Sea Systems Command CEL-TD_____I&c. ADDRESS (City, Store, and ZIP Code) 7b- ADDRESS (City, Stare, and ZIP Code)Washington, 20362_____Ba. NAME OF FUNDING/ISPONSORING 6b. OFFICE SYMBOL 9. PROCUREMIENT ;NSTRUMENT IDENTIFICATION NUMBERORGANIZATION j (if applicable)Na~val gqp A7qfgmc nWQ C1EL TD8c. ADDRESS (City, State, and ZIPCode) 10. SOURCE OF FUNDING 20362 PROGRAM PROJECT TASK WORK UNITW ahhgoELEMENT NO- NO. NO. ACCESSION TITLE (include Secury Classifiction). Reliability-Centered Maintenanrp Handchnork12. PERSONAL AUTHOR(S)I~a.

3 TYPE OF REPORT 13b TIME COVERED 14 DATE OF REPORT (Year Mhonth, D~y) 15. PAGE COUN1 TfI& SUPPt .MENTARY NOTATION FO ____T ___5IP17. ~ j~ C ota~ DaI tZ\. "Fu-C E~ 7ni on revers~e if necessary and identify by bock number)FIELD GROUP SUB-GROUPR elaibility- centered Maintance, RCMM aintenance19. A3 STrFACT (Continue on reverse if neces~sary and identify by block number) Handbook to introduce reader to preventive Maintenance -Program DesianSpecific applications related to ship as a supplement to MIL-P-2453A(navy)20. DISTRIBITiONIAVAILAILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATIONEIBUNCLASStFIED/UNLIMITED [I SAME AS RPT.]

4 C DTIC USERS iinrIaF;q fc22a NAME OF RESPONSIBLE INDIVIDUAL 22b TELEPHONE (include Area C d) 122C. OFFI(E SYMNBOLCEL-TD2 rt * 9Dt) FORMI 1473. 84 MAR 83 APR edition may be used ur. -.*.aused. SECURITY CLASSIFICATIONOF TIlS PACEAMl other editions are am pleased to introduce this Handbook as a proventool for developing improved preventive maintenanceprograms for Navy goal to have a fleet of reliable modern shipsrequires that we be effective in maintaining theirreadiness. Effective preventive Maintenance is a keyrequirement. As maintainers we must focus on not one,but two objectives -- do things right -- and do theright things.

5 This Handbook introduces Reliability-Centered Maintenance (RCM), a process designed to helpus achieve both of these hope you will find this Handbook both stimulatingand informative as you work to develop and implementRCM-based preventive Maintenance programs in CATOLA,Rear Admiral, United States NavyPrincipal Deputy Commanderfor LogisticsAccession ForNTSGRA iSDTIC TAB~~Unannounced [JustificationDistribution/AvailabilitY CodesAvai nd/oCONTENTSPREFACE ..I. INTRODUCTION TO RCM .. IA. History .. 1B. The Basis for RCM .. 2C. The Environment .. 3D. Scope .. 3!I. PRINCIPLES AND THEORY OF Maintenance .]

6 4A. What Kinds of Maintenance are There? .. 4B. What is a Function? ..4C. What is a Failure?.. 5D. Failure Detection .. 5E. Consequences of Failure ..6F. Failure Data .. 6G. Multiple Failures .. 7H. The Failure Process .. 8 Summary ..11 III. PREVENTIVE Maintenance TASKS..12A. Time-Directed Tasks .. 12B. Condition-Directed Tasks.. 13C. Failure-Finding Tasks .. 13D. Task Selection .. 13E. Servicing and Lubrication .. 14F. General Inspections .. 14 Summary .. 16IV. THE APPLICATION OF RCM .. 17A. Analyst and Staff Selection and Training .. 17B. Information Collection.. 19C. System Identification and Partitioning.

7 19D. Analysis of Systems ..22E. Default Strategy..22F. Periodicity .. 23G. Economics and Cost Effectiveness ..25V. DEVELOPING A PREVENTIVE Maintenance PROGRAM ..27A. Designing an RCM-Based Preventive MaintenanceProgram (MIL-P-24534A).. 27B. Master Systems and Subsystems Index(OPNAV 4790/114).. 29C. Functional Failure Analysis (OPNAV 4790/116). 29D. Additional Functionally Significant ItemSelection (OPNAV 4790/117) .. 30E. Functionally Significant Items Index(OPNAV 4790/118).. 32F. Failure Modes and Effects Analysis(OPNAV 4790/119) .. 32G. Hidden Functions Analysis (OPNAV 4790/127).

8 33H. Decision Logic Tree Analysis(OPNAV 4790/120)..33I. Servicing and Lubrication Analysis(OPNAV 4790/121)..36J. Safety-Related Design Change Recommendations(OPNAV 4790/122) .. 39 APPENDIX A -Glossary .. 40 APPENDIX B -Planned Maintenance SystemDevelopment Forms.. 42 PREFACE-This Handbook is d fourth edition of one printed early in1979 for use as a training aid. The content has been revisedconsiderably to:C(- Respond to experience gained during the training process;: -Directly support the requirements of MIL-P-24534A (Navy),The purpose of this Handbook - is to introduce you to theideas about preventive Maintenance , program design that are thefoundation for the method called $ Reliability-Centered Mainte-nance (RCM) Applying RCM requires an understanding of theseideas.)

9 Specific application also requires an understanding ofeach ship system, its failures, and the impact of these does not presume that hardware needs preventive maintenancebut uses knowledge about systems, their functions, and theirfailures to identify applicable and effective preventive mainte-nance Handbook is intended to supplement the applicableMilitary Specification(s), not to supplant provides an opportunity to apply reason -- not dogma1-- to preventive Maintenance program design. Well used, it willprovide significant benefits. Where data are limited, unstruc-tured judgement will always be offered as an alternative toanalysis.

10 Whatever the level of data available, a structured de-cision logic such as that described in this Handbook will providebetter decisions. RCM is not a cure-all, but it is a logical wayto attack important preventive Maintenance task needs using theavailable information and knowledge that can be brought to theproblem. Obviously, judgement has a role in this process. Justbe sure that you use it after collecting the facts, not insteadof collecting A belief handed down by authority as true and INTRODUCTION TO RCMA. HISTORYU ntil recently, very few of us had given much thought tological methods for designing preventive Maintenance programs.