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Reliability Centered Maintenance
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English
Intermediate
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Course Overview
RCM3 is an enhanced version of RCM2™, the trademark RCM methodology of Aladon. RCM3 is a process used to define the minimum required safe amount of maintenance, engineering and other risk management strategies to ensure a tolerable level of safety and environmental integrity and cost effective operational capability as specified in the organisation’s asset management standards.
RCM3 exceeds SAE standards and broadens RCM2 capability to align with more recent and international accepted ISO Management Systems (ISO 55000 and ISO 31000). Additionally, RCM3 is fully integrated with other Business Risk Management Systems like RBI and HAZOP.
RCM3 is no longer just another initiative, but a mainstream business risk management process that could become the most important management system for improving Process Safety and Asset Integrity. Our new risk-based methodology is the only process companies need to maintain and optimize all their assets (rotating and static).
RCM3 exceeds SAE standards and broadens RCM2 capability to align with more recent and international accepted ISO Management Systems (ISO 55000 and ISO 31000). Additionally, RCM3 is fully integrated with other Business Risk Management Systems like RBI and HAZOP.
RCM3 is no longer just another initiative, but a mainstream business risk management process that could become the most important management system for improving Process Safety and Asset Integrity. Our new risk-based methodology is the only process companies need to maintain and optimize all their assets (rotating and static).
Key Takeaways
1
Describe the principles of Reliability Centered Maintenance (RCM) and apply them to develop effective maintenance strategies that maximize asset reliability and availability while minimizing operational costs.
2
Analyze asset failure modes and their potential consequences, using tools such as FMEA and fault tree analysis, to identify critical equipment and prioritize maintenance activities.
3
Develop maintenance plans that include appropriate preventive, predictive, and corrective maintenance tasks, based on the analysis of failure modes and the criticality of assets.
4
Apply RCM concepts to develop and implement risk-based inspection plans, incorporating techniques such as non-destructive testing, vibration analysis, and thermography to identify and mitigate potential equipment failures.
5
Collaborate with cross-functional teams to implement RCM strategies and monitor their effectiveness, utilizing key performance indicators to continuously improve maintenance practices and reduce downtime.
The Aladon Network
We are a global network of asset reliability (RCM) professionals, certified in the delivery of team approach risk and reliability-based methodologies for all key assets in your organization. Our network has successfully and efficiently helped clients apply RCM-based practices in over 80 countries over the past three decades. We combine world-class asset care strategies to deliver change management, thanks to our extensive training and industrial expertise. Simply put, we give you tools to improve the way you manage maintenance and operations, controlling costs and boosting overall productivity. From Condition Assessment and Asset Life Information Management to our integrated risk based methodologies (RCM3 and RBI3), we focus on increasing asset value by reducing the cost of ownership and increasing return on asset (ROA) value.
Course Outline
Part 1
MORNING History of RCM
→ Introduction to RCM and RCM3
• Growing maintenance expectations
• Changing understanding of how equipment behaves
• New maintenance techniques
• International Standards
→ A Way Forward using RCM3
→ History of RCM
• Growing maintenance expectations
• Changing understanding of how equipment behaves
• New maintenance techniques
• International Standards
→ A Way Forward using RCM3
→ History of RCM
AFTERNOON: Functions
→ Function statements
• Performance standards (Multiple performance standards, quantitative performance standards, qualitative standards, absolute performance standards, variable performance standards, upper and lower limits)
• Different categories of functions
Exercise
• Describing functions and performance standards
• The operating context
Case Study
• Performance standards (Multiple performance standards, quantitative performance standards, qualitative standards, absolute performance standards, variable performance standards, upper and lower limits)
• Different categories of functions
Exercise
• Describing functions and performance standards
• The operating context
Case Study
Part 2
MORNING Failed States / Functional Failures
→ Failed states
→ Performance standards and failure
→ Who should set the standard?
→ Performance standards and failure
→ Who should set the standard?
Failure Modes
→ What is a failure mode?
• Failure modes (cause and mechanism) and the operating context
• What failure modes should be listed? (Human error)
• How much detail? (Causation)
• Describing failure modes
• Levels of analysis
Case Study
• Failure modes (cause and mechanism) and the operating context
• What failure modes should be listed? (Human error)
• How much detail? (Causation)
• Describing failure modes
• Levels of analysis
Case Study
Failure Effects
Describing failure effects, what to record (local effect, next level higher effect, end effect and potential worst cause effects) and what assumptions to make
AFTERNOON Failures Consequences
→ Defining worth doing criteria for:
• Hidden failures consequences
Safety and Environment consequences
• Operational consequences
• Non-Operational consequences
Hidden failures exercise
Failure consequences exercise
• Hidden failures consequences
Safety and Environment consequences
• Operational consequences
• Non-Operational consequences
Hidden failures exercise
Failure consequences exercise
Part 3
MORNING Risk Definition and Mitigation Risk Management Strategies Proactive Tasks
→ Defining technical criteria (including frequencies) for:
• On-condition tasks (Review of all the predictive technologies)
• Scheduled restoration tasks
• Scheduled discard tasks
• Combination of tasks Case Study
• On-condition tasks (Review of all the predictive technologies)
• Scheduled restoration tasks
• Scheduled discard tasks
• Combination of tasks Case Study
Risk Management Strategies II Default Tasks
→ Failure finding tasks (including frequency calculations)
→ No scheduled maintenance
→ One-time changes (Redesign, Training and Procedures)
Case Study
→ No scheduled maintenance
→ One-time changes (Redesign, Training and Procedures)
Case Study
AFTERNOON: Implementing RCM Decisions Applying RCM What RCM Achieves
Who Should Attend?
This highly practical and interactive course has been specifically designed for
Cross-functional teams involved in improvement projects
Senior engineering and technical managers
Maintenance managers, engineers and supervisors
Production or operational managers and engineers
Maintenance planners
Team leaders and supervisors
Safety managers
Reliability engineers
Those who want to improve the performance of their physical assets to optimise the return on their capital investments
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FAQ
What language will the course be taught in and what level of English do I need to take part in an LEORON training program?
Most of our public courses are delivered in English language. You need to be proficient in English to be able to fully participate in the workshop and network with other delegates. For in-house courses we have the capability to train in Arabic, Dutch, German and Portuguese.
Are LEORON Public courses certified by an official body/organization?
LEORON Institute partners with 20+ international bodies and associations.We also award continuing professional development credits (CPE/PDUs) for:1. NASBA (National Association of State Boards of Accountancy) 2. Project Management Institute PDUs 3. CISI credits 4. GARP credits 5. HRCI recertification credits 6. SHRM recertification credits
What is the deadline for registering to a public course?
The deadline to register for a public course is 14 days before the course starts. Kindly note that occasionally we do accept late registrations as well, but this needs to be confirmed with the project manager of the training program or with our registration desk that can be reached at +1071 4 1075 5711 or [email protected].
What does the course fee cover?
The course fee covers a premium training experience in a 5-star hotel, learning materials, lunches & refreshments, and for some courses, the certification fee and membership with the accrediting bodies.
Does LEORON give discounts?
Yes, we can provide discounts for group bookings. If you would like to discuss a discount on a corporate level, we will be happy to talk to you.