EN 60300-3-11:2009
(Main)Dependability management - Part 3-11: Application guide - Reliability centred maintenance
Dependability management - Part 3-11: Application guide - Reliability centred maintenance
IEC 60300-3-11:2009 provides guidelines for the development of failure management policies for equipment and structures using reliability centred maintenance (RCM) analysis techniques. This part serves as an application guide and is an extension of IEC 60300-3-10, IEC 60300-3-12 and IEC 60300-3-14. Maintenance activities recommended in all three standards, which relate to preventive maintenance, may be implemented using this standard. The previous edition was based on ATA1-MGS-3; whereas this edition applies to all industries and defines a revised RCM algorithm and approach to the analysis process.
Zuverlässigkeitsmanagement - Teil 3-11: Anwendungsleitfaden - Auf die Funktionsfähigkeit bezogene Instandhaltung
Gestion de la sûreté de fonctionnement - Partie 3-11: Guide d'application - Maintenance basée sur la fiabilité
La CEI 60300-3-11:2009 fournit des lignes directrices permettant l'élaboration d'une politique de gestion des défaillances pour des équipements et des structures, fondée sur une analyse de maintenance basée sur la fiabilité (MBF). Cette partie sert comme guide d'application et est un prolongement des CEI 60300-3-10, CEI 60300-3-12 et CEI 60300-3-14. Les activités de maintenance recommandées dans les trois normes et qui se rapportent à la maintenance préventive peuvent être mises en oeuvre en utilisant la présente norme. L'édition précédente était basée sur l'ATA1-MG-3; tandis que la présente édition est applicable à toutes les industries et elle définit un algorithme révisé du MBF et une méthode pour le processus d'analyse.
Upravljanje zagotovljivosti - 3-11. del: Navodilo za uporabo - Vzdrževanje s poudarkom na zanesljivosti (IEC 60300-3-11:2009)
Ta del IEC 60300 podaja smernice za razvoj politik upravljanja z napakami za opremo in konstrukcije z uporabo analiznih tehnik vzdrževanja s poudarkom na zanesljivost (RCM). Ta del služi kot vodilo za uporabo in je dodatek k IEC 60300-3-10, IEC 60300-3-12 in 60300-3-14. Vzdrževalne dejavnosti, ki so priporočene v vseh treh standardih, ki se nanašajo na preventivno vzdrževanje, se lahko izvedejo tako, da se uporabi ta standard. RCM metoda lahko velja za predmete, kot so cestna vozila, ladje, elektrarne, zrakoplovi in ostali sistemi, ki so narejeni iz opreme in konstrukcije, npr. zgradba, ogrodje zrakoplova ali ladijski trup. Običajno je oprema sestavljena iz številnih električnih, mehaničnih, instrumentnih ali nadzornih sistemov in podsistemov, ki se lahko po potrebi nadalje postopoma razdelijo na manjše skupine. Ta standard je omejen na uporabo RCM tehnik in ne vključuje vidikov glede podpore vzdrževanju, ki so zajeti v zgoraj navedenih standardih ali drugih standardih o zagotovljivosti in varnosti.
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
01-februar-2010
Upravljanje zagotovljivosti - 3-11. del: Navodilo za uporabo - Vzdrževanje s
poudarkom na zanesljivosti (IEC 60300-3-11:2009)
Dependability management - Part 3-11: Application guide - Reliability centred
maintenance (IEC 60300-3-11:2009)
Zuverlässigkeitsmanagement - Teil 3-11: Anwendungsleitfaden - Auf die
Funktionsfähigkeit bezogene Instandhaltung (IEC 60300-3-11:2009)
Gestion de la sûreté de fonctionnement - Partie 3-11: Guide d'application - Maintenance
basée sur la fiabilité (CEI 60300-3-11:2009)
Ta slovenski standard je istoveten z: EN 60300-3-11:2009
ICS:
03.120.01 Kakovost na splošno Quality in general
21.020 =QDþLOQRVWLLQQDþUWRYDQMH Characteristics and design of
VWURMHYDSDUDWRYRSUHPH machines, apparatus,
equipment
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
EUROPEAN STANDARD
EN 60300-3-11
NORME EUROPÉENNE
November 2009
EUROPÄISCHE NORM
ICS 03.100.40; 03.120.01
English version
Dependability management -
Part 3-11: Application guide -
Reliability centred maintenance
(IEC 60300-3-11:2009)
Gestion de la sûreté de fonctionnement - Zuverlässigkeitsmanagement -
Partie 3-11: Guide d'application - Teil 3-11: Anwendungsleitfaden -
Maintenance basée sur la fiabilité Auf die Funktionsfähigkeit bezogene
(CEI 60300-3-11:2009) Instandhaltung
(IEC 60300-3-11:2009)
This European Standard was approved by CENELEC on 2009-09-01. CENELEC members are bound to comply
with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard
the status of a national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and notified
to the Central Secretariat has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Cyprus, the
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: Avenue Marnix 17, B - 1000 Brussels
© 2009 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 60300-3-11:2009 E
Foreword
The text of document 56/1312/FDIS, future edition 2 of IEC 60300-3-11, prepared by IEC TC 56,
Dependability, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as
EN 60300-3-11 on 2009-09-01.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2010-06-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2012-09-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice
The text of the International Standard IEC 60300-3-11:2009 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following notes have to be added for the standards indicated:
IEC 61164 NOTE Harmonized as EN 61164:2004 (not modified).
IEC 61649 NOTE Harmonized as EN 61649:2008 (not modified).
IEC 61709 NOTE Harmonized as EN 61709:1998 (not modified).
IEC 62308 NOTE Harmonized as EN 62308:2006 (not modified).
ISO 9000 NOTE Harmonized as EN ISO 9000:2005 (not modified).
__________
- 3 - EN 60300-3-11:2009
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
NOTE When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD
applies.
Publication Year Title EN/HD Year
IEC 60050-191 1990 International Electrotechnical Vocabulary - -
(IEV) -
Chapter 191: Dependability and quality of
service
1) 2)
IEC 60300-3-2 - Dependability management - EN 60300-3-2 2005
Part 3-2: Application guide - Collection of
dependability data from the field
1)
IEC 60300-3-10 - Dependability management - - -
Part 3-10: Application guide - Maintainability
1) 2)
IEC 60300-3-12 - Dependability management - EN 60300-3-12 2004
Part 3-12: Application guide - Integrated
logistic support
1) 2)
IEC 60300-3-14 - Dependability management - EN 60300-3-14 2004
Part 3-14: Application guide - Maintenance
and maintenance support
1) 2)
IEC 60812 - Analysis techniques for system reliability - EN 60812 2006
Procedure for failure mode and effects
analysis (FMEA)
1)
Undated reference.
2)
Valid edition at date of issue.
IEC 60300-3-11 ®
Edition 2.0 2009-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Dependability management –
Part 3-11: Application guide – Reliability centred maintenance
Gestion de la sûreté de fonctionnement –
Partie 3-11: Guide d'application – Maintenance basée sur la fiabilité
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
X
CODE PRIX
ICS 03.100.40; 03.120.01 ISBN 2-8318-1045-3
– 2 – 60300-3-11 © IEC:2009
CONTENTS
FOREWORD.4
INTRODUCTION.6
1 Scope.7
2 Normative references.7
3 Terms, definitions and abbreviations .7
3.1 Definitions .8
3.2 Abbreviations.11
4 Overview .11
4.1 General .11
4.2 Objectives .12
4.3 Types of maintenance.14
5 RCM initiation and planning .15
5.1 Objectives for conducting an RCM analysis.15
5.2 Justification and prioritization.16
5.3 Links to design and maintenance support.16
5.4 Knowledge and training.17
5.5 Operating context .17
5.6 Guidelines and assumptions .18
5.7 Information requirements .19
6 Functional failure analysis.20
6.1 Principles and objectives .20
6.2 Requirements for definition of functions .20
6.2.1 Functional partitioning.20
6.2.2 Development of function statements.20
6.3 Requirements for definition of functional failures .21
6.4 Requirements for definition of failure modes .21
6.5 Requirements for definition of failure effects .22
6.6 Criticality .22
7 Consequence classification and RCM task selection .23
7.1 Principles and objectives .23
7.2 RCM decision process .23
7.3 Consequences of failure .26
7.4 Failure management policy selection.26
7.5 Task interval.27
7.5.1 Data sources .27
7.5.2 Condition monitoring .28
7.5.3 Scheduled replacement and restoration.29
7.5.4 Failure finding.30
8 Implementation .30
8.1 Maintenance task details .30
8.2 Management actions.30
8.3 Feedback into design and maintenance support .30
8.4 Rationalization of tasks.33
8.5 Implementation of RCM recommendations .34
8.6 Age exploration .34
8.7 Continuous improvement .34
60300-3-11 © IEC:2009 – 3 –
8.8 In-service feedback .35
Annex A (informative) Criticality analysis .37
Annex B (informative) Failure finding task intervals.40
Annex C (informative) Failure patterns .42
Annex D (informative) Application of RCM to structures .44
Bibliography .47
Figure 1 – Overview of the RCM process.12
Figure 2 – Evolution of an RCM maintenance programme.14
Figure 3 – Types of maintenance tasks .15
Figure 4 – Relationship between RCM and other support activities.17
Figure 5 – RCM decision diagram.25
Figure 6 – P-F Interval .28
Figure 7 – ILS management process and relationship with RCM analysis .32
Figure 8 – Risk versus cost considerations for rationalization of tasks .33
Figure 9 – RCM continuous improvement cycle.35
Figure C.1 – Dominant failure patterns .42
Table A.1 – Example of a criticality matrix .39
Table C.1 – Failure pattern categories and frequency of occurrence .43
– 4 – 60300-3-11 © IEC:2009
INTERNATIONAL ELECTROTECHNICAL COMMISSION
_____________
DEPENDABILITY MANAGEMENT –
Part 3-11: Application guide –
Reliability centred maintenance
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with an IEC Publication.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60300-3-11 has been prepared by IEC technical committee 56:
Dependability.
This second edition cancels and replaces the first edition, published in 1999, and constitutes a
technical revision.
The previous edition was based on ATA -MGS-3; whereas this edition applies to all industries
and defines a revised RCM algorithm and approach to the analysis process.
___________
The Air Transport Association of America.
60300-3-11 © IEC:2009 – 5 –
The text of this standard is based on the following documents:
FDIS RVD
56/1312/FDIS 56/1320/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
A list of all parts in the IEC 60300 series, under the general title Dependability management
can be found on the IEC website.
The committee has decided that the contents of this publication will remain unchanged until the
maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be:
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 6 – 60300-3-11 © IEC:2009
INTRODUCTION
Reliability centred maintenance (RCM) is a method to identify and select failure management
policies to efficiently and effectively achieve the required safety, availability and economy of
operation. Failure management policies can include maintenance activities, operational
changes, design modifications or other actions in order to mitigate the consequences of failure.
RCM was initially developed for the commercial aviation industry in the late 1960s, resulting in
the publication of ATA-MGS-3 [1] . RCM is now a proven and accepted methodology used in a
wide range of industries.
RCM provides a decision process to identify applicable and effective preventive maintenance
requirements, or management actions, for equipment in accordance with the safety,
operational and economic consequences of identifiable failures, and the degradation
mechanism responsible for those failures. The end result of working through the process is a
judgement as to the necessity of performing a maintenance task, design change or other
alternatives to effect improvements.
The basic steps of an RCM programme are as follows:
a) initiation and planning;
b) functional failure analysis;
c) task selection;
d) implementation;
e) continuous improvement.
All tasks are based on safety in respect of personnel and environment, and on operational or
economic concerns. However, it should be noted that the criteria considered will depend on the
nature of the product and its application. For example, a production process will be required to
be economically viable, and may be sensitive to strict environmental considerations, whereas
an item of defence equipment should be operationally successful, but may have less stringent
safety, economic and environmental criteria.
Maximum benefit can be obtained from an RCM analysis if it is conducted at the design stage,
so that feedback from the analysis can influence design. However, RCM is also worthwhile
during the operation and maintenance phase to improve existing maintenance tasks, make
necessary modifications or other alternatives.
Successful application of RCM requires a good understanding of the equipment and structure,
as well as the operational environment, operating context and the associated systems, together
with the possible failures and their consequences. Greatest benefit can be achieved through
targeting of the analysis to where failures would have serious safety, environmental, economic
or operational effects.
___________
Figures in square brackets refer to the bibliography.
60300-3-11 © IEC:2009 – 7 –
DEPENDABILITY MANAGEMENT –
Part 3-11: Application guide –
Reliability centred maintenance
1 Scope
This part of IEC 60300 provides guidelines for the development of failure management policies
for equipment and structures using reliability centred maintenance (RCM) analysis techniques.
This part serves as an application guide and is an extension of IEC 60300-3-10, IEC 60300-3-
12 and IEC 60300-3-14. Maintenance activities recommended in all three standards, which
relate to preventive maintenance, may be implemented using this standard.
The RCM method can be applied to items such as ground vehicles, ships, power plants,
aircraft, and other systems which are made up of equipment and structure, e.g. a building,
airframe or ship's hull. Typically, equipment comprises a number of electrical, mechanical,
instrumentation or control systems and subsystems which can be further broken down into
progressively smaller groupings, as required.
This standard is restricted to the application of RCM techniques and does not include aspects
of maintenance support, which are covered by the above-mentioned standards or other
dependability and safety standards.
2 Normative references
The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.
IEC 60050-191:1990, International Electrotechnical Vocabulary – Chapter 191: Dependability
and quality of service
IEC 60300-3-2, Dependability management – Part 3-2: Application guide – Collection of
dependability data from the field
IEC 60300-3-10, Dependability management – Part 3-10: Application guide – Maintainability
IEC 60300-3-12, Dependability management – Part 3-12: Application guide – Integrated logistic
support
IEC 60300-3-14, Dependability management – Part 3-14: Application guide – Maintenance and
maintenance support
IEC 60812, Analysis techniques for system reliability – Procedure for failure mode and effects
analysis (FMEA)
3 Terms, definitions and abbreviations
For the purposes of this document, the terms and definitions of IEC 60050-191 apply, together
with the following.
– 8 – 60300-3-11 © IEC:2009
3.1 Definitions
3.1.1
age exploration
systematic evaluation of an item based on analysis of collected information from in-service
experience to determine the optimum maintenance task interval
NOTE The evaluation assesses the item's resistance to a deterioration process with respect to increasing age or
usage.
3.1.2
criticality
severity of effect of a deviation from the specified function of an item, with respect to specified
evaluation criteria
NOTE 1 The extent of effects considered may be limited to the item itself, to the system of which it is a part, or
range beyond the system boundary.
NOTE 2 The deviation may be a fault, a failure, a degradation, an excess temperature, an excess pressure, etc.
NOTE 3 In some applications, the evaluation of criticality may include other factors such as the probability of
occurrence of the deviation, or the probability of detection.
3.1.3
damage-tolerant
capable of sustaining damage and continuing to function as required, possibly at reduced
loading or capacity
3.1.4
failure (of an item)
loss of ability to perform as required
3.1.5
failure effect
consequence of a failure mode on the operation, function or status of the item
3.1.6
failure management policy
maintenance activities, operational changes, design modifications or other actions in order to
mitigate the consequences of failure
3.1.7
function
intended purpose of an item as described by a required standard of performance
3.1.8
failure mode
manner in which failure occurs
NOTE A failure mode may be defined by the function lost or the state transition that occurred.
3.1.9
failure-finding task
scheduled inspection or specific test used to determine whether a specific hidden failure has
occurred
3.1.10
functional failure
reduction in function performance below desired level
60300-3-11 © IEC:2009 – 9 –
3.1.11
hidden failure mode
failure mode whose effects do not become apparent to the operator under normal
circumstances
3.1.12
indenture level
level of subdivision of an item from the point of view of a maintenance action
NOTE 1 Examples of indenture levels could be a subsystem, a circuit board, a component.
NOTE 2 The indenture level depends on the complexity of the item’s construction, the accessibility to subitems,
skill level of maintenance personnel, test equipment facilities, safety considerations, etc.
[IEV 191-07-05:1990]
3.1.13
inspection
identification and evaluation of the actual condition against a specification
3.1.14
maintenance action
maintenance task
sequence of elementary maintenance activities carried out for a given purpose
NOTE Examples include diagnosis, localization, function check-out, or combinations thereof.
3.1.15 tem
part, component, device, subsystem, functional unit, equipment or system that can be
individually considered
NOTE 1 An item may consist of hardware, software or both, and may also, in particular cases, include people.
Elements of a system may be natural or man-made material objects, as well as modes of thinking and the results
thereof (e.g. forms of organization, mathematical methods and programming languages).
NOTE 2 In French the term "entité" is preferred to the term "dispositif” due to its more general meaning. The term
"dispositif' is also the common equivalent for the English term "device".
NOTE 3 In French the term "individu" is used mainly in statistics.
NOTE 4 A group of items, e.g. a population of items or a sample, may itself be considered as an item.
NOTE 5 A software item may be a source code,an object code, a job control code, control data, or a collection of
these.
3.1.16
maintenance concept
interrelationship between the maintenance echelons, the indenture levels and the levels of
maintenance to be applied for the maintenance of an item
3.1.17
maintenance echelon
position in an organization where specified levels of maintenance are to be carried out on an
item
NOTE 1 Examples of maintenance echelons are: field, repair shop, and manufacturer.
NOTE 2 The maintenance echelon is characterized by the level of skill of the personnel, the facilities available,
the location, etc.
[IEV 191-07-04:1990]
– 10 – 60300-3-11 © IEC:2009
3.1.18
maintenance policy
general approach to the provision of maintenance and maintenance support based on the
objectives and policies of owners, users and customers
3.1.19
maintenance programme
list of all the maintenance tasks developed for a system for a given operating context and
maintenance concept
3.1.20
operating context
circumstances in which an item is expected to operate
3.1.21
potential failure
identifiable condition that indicates that a functional failure is either about to occur or is in the
process of occurring
3.1.22
potential failure – functional failure (P-F) interval
interval between the point at which a potential failure becomes detectable and the point at
which it degrades into a functional failure
3.1.23
reliability centred maintenance
method to identify and select failure management policies to efficiently and effectively achieve
the required safety, availability and economy of operation.
3.1.24
safe life
age before which no failures are expected to occur
3.1.25
system
set of interrelated or interacting elements
[ISO 9000, 3.2.1][2]
NOTE 1 In the context of dependability, a system will have:
a) a defined purpose expressed in terms of required functions;
b) stated conditions of operation/use;
c) defined boundaries.
NOTE 2 The structure of a system may be hierarchical.
3.1.26
useful life
time interval to a given instant when a limited state is reached
NOTE 1 Limited state may be a function of failure intensity, maintenance support requirement, physical condition,
age, obsolesence, etc.
NOTE 2 The time interval may start at first use, at a subsequent instant, i.e. remaining useful life.
60300-3-11 © IEC:2009 – 11 –
3.2 Abbreviations
FMEA Failure mode and effects analysis
FMECA Failure mode, effects and criticality analysis
ILS Integrated logistic support
HUMS Health usage management systems
LORA Level of repair analysis
NDI Non-destructive inspection
RCM Reliability centred maintenance
4 Overview
4.1 General
The RCM process is fully described in this standard and provides information on each of the
following elements:
a) RCM initiation and planning;
b) functional failure analysis;
c) task selection;
d) implementation;
e) on-going improvement.
Figure 1 shows the overall RCM process, divided into five steps. It can be seen from this figure
that RCM provides a comprehensive programme that addresses not just the analysis process
but also the preliminary and follow-on activities necessary to ensure that the RCM effort
achieves the desired results. The RCM process can be applied to all types of systems. Annex
D provides guidance on how the process should be interpreted for structures for which the
failure mechanisms and resultant tasks are more narrowly defined.
– 12 – 60300-3-11 © IEC:2009
1. INITIATION AND PLANNING
a) Determine the boundaries and objectives
of the analysis
OUTPUTS
b) Determine the content of the analysis
c) Identify the specialist knowledge and experience
available, responsibilities, the need for outside Analysis plan and
expertise and any training requirements operating context
d) Develop operating context for the item(s)
2. FUNCTIONAL FAILURE ANALYSIS
a) Collect and analyse any field data
and available test data
b) Perform functional partitioning
c) Identify functions, functional failures,
failure modes, effects and criticality
FMEA/FMECA
3. TASK SELECTION
a) Evaluate failure consequences
b) Select the most appropriate and effective failure
Maintenance
management policy
tasks
c) Determine task interval, if appropriate
4. IMPLEMENTATION
a) Identify maintenance task details
b) Prioritize and implement other actions
c) Rationalize task intervals
Maintenance
d) Initial age exploration programme
5. CONTINUOUS IMPROVEMENT
a) Monitor maintenance effectiveness
Field data
b) Monitor against safety, operational and
economic targets
c) Perform age exploration
IEC 913/09
Figure 1 – Overview of the RCM process
4.2 Objectives
As part of a maintenance policy, the objectives of an effective preventive maintenance
programme are as follows:
a) to maintain the function of an item at the required dependability performance level within
the given operating context;
b) to obtain the information necessary for design improvement or addition of redundancy for
those items whose reliability proves inadequate;
c) to accomplish these goals at a minimum total LCC, including maintenance costs and the
costs of residual failures;
60300-3-11 © IEC:2009 – 13 –
d) to obtain the information necessary for the ongoing maintenance programme which
improves upon the initial programme, and its revisions, by systematically assessing the
effectiveness of previously defined maintenance tasks. Monitoring the condition of specific
safety, critical or costly components plays an important role in the development of a
programme.
These objectives recognize that maintenance programmes, as such, cannot correct design
deficiencies in the safety and reliability levels of the equipment and structures. The
maintenance programme can only minimize deterioration and restore the item to its design
levels. If the reliability intrinsic levels are found to be unsatisfactory, design modification,
operational changes or procedural changes (such as training programmes) may be necessary
to achieve the desired performance.
RCM improves maintenance effectiveness and provides a mechanism for managing
maintenance with a high degree of control and awareness. Potential benefits can be
summarized as follows:
1) system dependability can be increased by using more appropriate maintenance activities;
2) overall costs can be reduced by more efficient planned maintenance effort;
3) a fully documented audit trail is produced;
4) a process to review and revise the failure management policies in the future can be
implemented with relatively minimum effort;
5) maintenance managers have a management tool which enhances control and direction;
6) maintenance organization obtains an improved understanding of its objectives and
purpose and the reasons for which it is performing the scheduled maintenance tasks.
The maintenance programme is a list of all the maintenance tasks developed for a system for a
given operating context and maintenance concept, including those arising from the RCM
process. Maintenance programmes are generally composed of an initial programme and an on-
going, "dynamic" programme. Figure 2 shows the principal factors which need to be considered
in the development stage, that is before operation, and those which are used to update the
programme, based on operational experience, once the product is in service.
The initial maintenance programme, which is often a collaborative effort between the supplier
and the user, is defined prior to operation and may include tasks based on the RCM
methodology. The on-going maintenance programme, which is a development of the initial
programme, is initiated as soon as possible by the user once operation begins, and is based on
actual degradation or failure data, changes in operating context, advances in technology,
materials, maintenance techniques and tools. The on-going programme is maintained using
RCM methodologies. The initial maintenance programme is updated to reflect changes made to
the programme during operation.
An initial RCM programme may be initiated when the product is in service, in order to renew
and improve on an existing maintenance programme, based on experience or manufacturer's
recommendations, but without the benefit of a standard approach such as RCM.
– 14 – 60300-3-11 © IEC:2009
Analysis of maintenance
Specification Maintenance inputs
programme
Failure data
Function Task development (RCM)
Maintenance procedures
Operating context Task frequency (RCM)
Maintenance tools
Availability, reliability and Maintenance resources
Supplier recommendations
safety targets
INITIAL MAINTENANCE PROGRAMME
Before operation
During operation
ON-GOING MAINTENANCE PROGRAMME
Maintenance data/maintainer input New technology
Operational data/operator input New materials
Failure data
New maintenance techniques and tools
IEC 914/09
Figure 2 – Evolution of an RCM maintenance programme
4.3 Types of maintenance
Different approaches are taken to maintenance tasks as illustrated in Figure 3. There are two
types of maintenance action: preventive and corrective.
Preventive maintenance is undertaken prior to failure. This can be condition-based, which can
be achieved by monitoring the condition until failure is imminent, or by functional checks to
detect failure of hidden functions. Preventive maintenance can also be predetermined, based
on a fixed interval (such as calendar time, operating hours, number of cycles) consisting of
scheduled refurbishment or replacement of an item or its components.
Corrective maintenance restores the functions of an item after failure has occurred or
performance fails to meet stated limits. Some failures are acceptable if the consequences of
failure (such as production loss, safety, environmental impact, failure cost) are tolerable
compared to the cost of preventive maintenance and the subsequent loss due to failure. This
results in a planned run-to-failure approach to maintenance.
Preventive maintenance is normally scheduled or based on a predetermined set of conditions
while corrective maintenance is unscheduled. It is not unusual to defer corrective maintenance
for a later convenient time when redundancy preserves function. RCM identifies the optimal
preventive and corrective maintenance tasks.
60300-3-11 © IEC:2009 – 15 –
MAINTENANCE
Before failure After failure
Corrective maintenance
Preventive maintenance
Condition-based
Predetermined
Scheduled Immediate Deferred
Condition monitoring Scheduled
Failure finding
replacement maintenance maintenance
restoration
and inspection
If not If not
OK OK
Cleaning, lubrication, adjustment, calibration, repair, refurbishment, replacement
IEC 915/09
Figure 3 – Types of maintenance tasks
5 RCM initiation and planning
5.1 Objectives for conducting an RCM analysis
The first phase of planning an RCM analysis is to determine the need and extent for the study,
taking into consideration the following objectives as a minimum:
a) establish optimal maintenance tasks for the item;
b) identify opportunities for design improvement;
c) evaluate where the current maintenance tasks are ineffective, inefficient or inappropriate;
d) identify the dependability improvements.
The process of assessing the need for RCM analysis should be a regular management activity
within the organization’s programme of continuous maintenance improvement.
A broad analysis of available data within the organization’s maintenance management system
will identify target systems, where the current failure management policy has failed or is
suspect. Data indicating the following parameters will identify potential items:
1) changes in the operating context;
2) inadequate availability and/or reliability;
3) safety incidents;
4) unacceptably high preventive and/or corrective maintenance man hours;
5) backlog of maintenance work;
6) excessive maintenance cost;
7) unacceptably high ratio of “corrective to preventive” maintenance;
8) new maintenance techniques;
9) item technology changes.
– 16 – 60300-3-11 © IEC:2009
Total reliance on data within a maintenance management system may be misleading and
should be supported by additional evidence from maintenance personnel or a system
inspection to reveal any features that may not be included in the data. An assessment of the
completeness and accuracy of information available should be included in the RCM planning
process.
There are other advantages in engaging maintenance personnel in the RCM team; they will
become familiar with the item and provide opportunities to understand the operating context
and have a direct discussion regarding existing maintenance, failure modes and failure
patterns (see Annex C).
5.2 Justification and prioritization
As part of a wider maintenance policy, an RCM analysis should only be implemented when
there is confidence that it can be cost effective or when direct commercial cost considerations
are overridden by other critical objectives, such as requirements for safety and the
environment. These factors should be considered over the entire life time of the item.
Those discrete systems that are judged to have an effect on the overall business goals will be
identified as in need of analysis. The selection and priority by which they should be addressed
should be based on a wide range of criteria such as:
a) maintenance efficiency;
b) dependability improvement;
c) design/operation change.
The priority of systems will depend on the priority of the organization’s business objectives.
The methods used to select and prioritize the systems can be divided into:
1) qualitative methods based on past history and collective engineering judgement,
2) quantitative methods, based on quantitative criteria, such as criticality rating, safety
factors, probability of failure, failure rate, life cycle cost, etc., used to evaluate the
importance of system degradation/failure on equipment safety, performance and costs.
Implementation of this approach is facilitated when appropriate models and data sources
exist,
3) combination of qualitative and quantitative methods.
The purpose of this activity is to produce a listing of items ranked by criticality and priority.
5.3 Links to design and maintenance support
The majority of the maintenance support requirements for a system is decided at the initial
design, and hence the planning for maintenance and maintenance support should be
considered as early as possible so that trade-offs can be considered between functional needs,
capability, life cycle cost, dependability and safety.
Maintenance and maintenance support should be considered during all phases of the life cycle.
The specific tasks that should be performed are given in IEC 60300-3-14 and maintainability
aspects are given in IEC 60300-3-10.
The approach for determining the total support requirements during the life of the system prior
to initial operation is known as “integrated logistic support” (ILS) and this should be conducted
in accordance with IEC 60300-3-12. Figure 4 illustrates the relationship between RCM and
other support and analysis activities.
60300-3-11 © IEC:2009 – 17 –
IEC 60300-3-10 IEC 60300-3-12 IEC 60300-3-14
Dependability management Dpendability management Dependability management
Part 3-10: Application guide – Part 3-12: Application guide – Part 3-14: Application guide –
Maintainability Integrated logistic support Maintenance and maintenance support
Supports Supports Supports
IEC 60300-3-11
Dependability mangement
Part 3-11: Application guide –
Reliability centred maintenance
Supports
IEC 60812
Analysis techniques for system
reliability – Procedure for failure mode
and effects analysis (FMEA)
IEC 916/09
Figure 4 – Relationship between RCM and other support activities
5.4 Knowledge and training
An RCM analysis requires specialist knowledge and experience with the item and its operating
context. The analysis requi
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