Decoding Reliability-Centered Maintenance Process for Manufacturing Industries: 9th Discipline of World Class Maintenance Management - The 12 Discipli

There are cases where breakdowns and failures are not the primary cause of equipment downtime, especially in manufacturing industries. Although RCM is a popular maintenance strategy, many manufacturing industries are still not implementing this process and continue to remain stuck in their PM tasks activities. The main reason why I wrote this book is that doing RCM in a manufacturing plant is a bit different from doing RCM in oil and gas, power plants, and other similar plants because their equipment losses are different. Although the process on how RCM is done will be the same. If you worked in a semiconductor plant, breakdowns and failures are not the main issues on the machines, but minor stoppages, changeover, and quality problems are. You must know the boundary between what RCM can address and what it cannot. RCM will address failures and breakdowns by proposing maintenance tasks; it is not designed to address every possible equipment loss. What I am saying is that failures are just a subset of the entire equipment losses. Suppose you have chronic quality problems caused by the equipment; RCM can address some of them, but not all, since Quality problems and defects are much broader than breakdown and failures. I have a detailed explanation of what particular losses RCM can and cannot address in Chapter 3.3.2 of this book. This book is written to help and provide detailed guidelines for manufacturing industries on implementing RCM on their machines, equipment, and assets. Some of the highlights of this book include:27 Frequently Asked Questions (FAQ) on RCM22 Tips on Implementing RCM- 15 Don'ts About RCMWhy the RCM Preparatory Stage is ImportantDetailed Guidelines in Doing the RCM Preparatory StepCan RCM Address All Equipment Losses?Actual Case Study on RCM: Air Handling Unit CaseRole of Operators in the RCM AnalysisHow to Integrate RCM into the TPM ProcessBonus: RCM Forms I used in Excel FormatThe RCM and TPM Crossroads - Do they have different or the same pathsStrengthening the SAE JA1011 CriteriaAddressing MRO Spare Parts after Implementing RCMHow to Determine the Correct Interval for PM, PdM, FFT, and Switching Standby ComponentsMRO Decision Diagram on Whether to Stock or Not to StockDifference Between a Failure Mode and a Root CauseSecondary Tasks for Doing On-Condition TasksDetailed Guidelines in Writing the RCM Decision Worksheet ExplainedDetailed Guidelines in Writing the RCM Information Worksheet ExplainedDetailed Guidelines in performing Horizontal Replication for Similar Equipment with the Same Operating ContextDetailed Guidelines in Conducting the RCM Audit and many more . . .In this book, I have explained two definitions of RCM, which is looking on the equipment side and the human side of doing it. From an equipment point of view, Reliability-Centered Maintenance is a process used to determine any physical asset's maintenance tasks, decisions, and requirements in its current or present operating context. It is also a process used to determine what must be done to ensure that any physical assets continue to do whatever their users want them to do in their present operating context. On the other end, from a human point of view, RCM is a way or process of capturing and extracting the knowledge, understanding, experience, and wisdom of the most experienced people in the plant and transforming it into a living document and their legacy. In most cases, when these good old folks go away and retired for good, they bring everything they know to their grave. We just want to put a stop to this never-ending cycle. I have also explained in this book how to implement RCM more successfully by restoring the equipment first.