ABB - Reliability-Centered Maintenance

Summary

This video introduces Reliability-Centered Maintenance (RCM), a world-class maintenance approach for optimizing assets in industries like manufacturing and process automation. It covers three key topics: equipment criticality analysis, failure modes and effects analysis (FMEA), and how to implement RCM. The presenter, Dave Bureaus from ABB, highlights the balance between preventive, reactive, and proactive maintenance, emphasizing the importance of maintaining equipment efficiently without inducing failure. Safety, production impact, and cost are central to the criticality analysis. ABB's tools, like Service Pro and advanced services, are showcased as essential for successful RCM implementation.

Takeaways

• 🔧 Reliability-centered maintenance (RCM) is a high-level strategy designed to optimize all assets in a facility by using a variety of maintenance approaches.
• 🏭 RCM is considered the world-class maintenance approach for industries such as manufacturing and process industries.
• 📉 Preventive maintenance can reduce unplanned repairs and lower overall maintenance costs but doing too much can also induce failures or increase costs.
• ⚙️ Before RCM, common strategies included reactive maintenance (fix after failure), preventive maintenance (regular maintenance), proactive maintenance (easy-to-maintain designs), and predictive maintenance (using technology to predict failures).
• 🎯 RCM only selects the appropriate maintenance strategy for each piece of equipment, and sometimes it may not require any maintenance if the equipment is low-cost or redundant.
• 🛠️ The three key steps in RCM are: preserving equipment functionality by determining criticality, identifying and prioritizing failure modes, and implementing the correct maintenance strategy.
• 🚨 Criticality analysis must always prioritize safety, followed by environmental, production, maintenance costs, and the effect on other systems.
• 📊 Failure Modes and Effects Analysis (FMEA) identifies potential failures and the causes, ranking them based on likelihood and impact, and recommends actions to prevent or address them.
• 👥 Successful RCM implementation requires a cross-functional team from various departments, including mechanical maintenance, process control, operations, and engineering.
• 💻 Tools like ABB’s ServicePro and ServicePort help analyze maintenance data, identify critical equipment, and assist in benchmarking performance to improve reliability-centered maintenance practices.

Q & A

What is Reliability-Centered Maintenance (RCM)?

Reliability-Centered Maintenance (RCM) is a high-level maintenance strategy designed to optimize the performance of all assets in a facility. It integrates various maintenance approaches to create a system-specific strategy that ensures efficient plant operation.

Why is RCM considered the world-class maintenance approach?

RCM is regarded as world-class because it balances preventive, reactive, and predictive maintenance strategies. It ensures that maintenance efforts are efficient and cost-effective while minimizing unplanned downtime and costly failures.

What are the three main steps in effective RCM implementation?

The three main steps are: 1) Preserve equipment functionality by establishing equipment criticality levels. 2) Identify and prioritize failure modes for each piece of equipment. 3) Implement RCM by selecting the right maintenance approaches based on equipment criticality and failure analysis.

What is the importance of finding a 'sweet spot' in preventive maintenance?

The 'sweet spot' in preventive maintenance refers to doing just the right amount of maintenance. Too little maintenance can result in unplanned repairs, while too much can lead to induced failures or unnecessary costs.

What are the key factors to consider when determining equipment criticality?

The key factors include: 1) Safety risks, 2) Environmental impact, 3) Production stoppages, 4) Maintenance expenses, 5) System-wide effects, and 6) Redundancy within the system.

How does Failure Modes and Effects Analysis (FMEA) contribute to RCM?

FMEA helps identify potential failure modes for each component, understand the underlying causes, and determine the likelihood and impact of those failures. This analysis guides the selection of appropriate maintenance strategies for each piece of equipment.

What is the difference between reactive, preventive, and predictive maintenance?

Reactive maintenance involves fixing equipment after it breaks. Preventive maintenance schedules regular checks to avoid breakdowns. Predictive maintenance uses technology to monitor equipment performance in real-time and detect issues before they cause failures.

Why is safety the top priority in equipment criticality analysis?

Safety is prioritized because equipment failures can lead to severe consequences, including loss of life or serious injuries. Ensuring safe operations prevents catastrophic incidents and maintains a safe working environment.

What role does ABB’s Service Pro play in supporting RCM?

ABB's Service Pro helps customers manage their maintenance processes by providing a computerized maintenance management system (CMMS). It includes preventive maintenance routines, criticality analysis, and benchmarking tools to optimize asset management.

How does ABB's advanced services powered by Service Port assist in RCM?

ABB’s advanced services use real-time data from systems like Harmony control and quality control systems to identify and prioritize maintenance needs. This data-driven approach supports reliability-centered maintenance by enabling proactive decision-making.

Outlines

00:00

🔧 Introduction to Reliability-Centered Maintenance (RCM)

Dave Bureaus, a global product marketing manager for ABB, introduces Reliability-Centered Maintenance (RCM), a high-level maintenance strategy aimed at optimizing all assets within a facility. He explains the importance of preventive maintenance and achieving a balance to avoid both under- and over-maintenance. The discussion highlights how RCM differs from reactive and preventive maintenance, aiming to maintain equipment efficiently while minimizing costs.

05:02

⚠️ Equipment Criticality and Safety Considerations

This section emphasizes the criticality of equipment, with safety being the top priority in maintenance strategies. Dave presents a case of a refinery explosion in Asia to illustrate the consequences of maintenance failures. He then explains the five levels of equipment criticality, with each level considering factors like safety, environmental impact, production stoppage, maintenance costs, system effects, and redundancy.

10:03

📊 Failure Modes and Effects Analysis (FMEA)

Dave delves into the Failure Modes and Effects Analysis (FMEA) process, which identifies potential failure modes in equipment and their causes. He uses the example of a compressed air system to demonstrate how components like compressors and motors may fail, along with the mechanisms behind these failures. The FMEA process includes ranking the likelihood of failure and assessing the impact on production, followed by recommendations such as regular lubrication to prevent bearing failure.

15:05

🏭 Implementing Reliability-Centered Maintenance

This paragraph outlines the steps for effectively implementing Reliability-Centered Maintenance (RCM) in a plant. The process involves forming a cross-functional team, analyzing current maintenance processes, and setting clear business goals like increasing production or reducing maintenance costs. Dave stresses the importance of assigning responsibilities and integrating RCM into a computerized maintenance management system (CMMS) for smooth operations.

Keywords

💡Reliability Centered Maintenance (RCM)

Reliability Centered Maintenance (RCM) is a maintenance strategy focused on optimizing the performance and reliability of equipment in a facility. It incorporates different maintenance approaches, such as preventive, proactive, and reactive maintenance, depending on the equipment’s needs. The goal is to balance maintenance efforts to avoid both excessive preventive maintenance and unplanned repairs. RCM plays a central role in the video as the recommended approach for industries to improve efficiency and safety.

💡Preventive Maintenance

Preventive maintenance refers to regular, scheduled maintenance activities aimed at preventing equipment failure. The concept is discussed in the video as an important part of RCM, where the goal is to reduce unplanned repairs and emergency breakdowns. However, the video also warns about doing too much preventive maintenance, which can lead to unnecessary costs or even induce failures.

💡Reactive Maintenance

Reactive maintenance involves repairing equipment only after a failure has occurred. This approach is described as inefficient in the video since it does not prevent breakdowns or take cost into account. The video highlights how reactive maintenance is popular because it is simple—fixing things only when they break—but it is not optimal for long-term performance and reliability.

💡Criticality Analysis

Criticality analysis is a process of determining how critical a piece of equipment is to the overall operation, taking into account factors like safety, environmental impact, and production stoppage. The video emphasizes its importance in RCM as the first step in prioritizing maintenance efforts. Equipment with higher criticality, such as those with safety implications or costly repairs, should receive more attention.

💡Failure Modes and Effects Analysis (FMEA)

Failure Modes and Effects Analysis (FMEA) is a systematic approach to identifying potential failure points in equipment and assessing their likely effects. The video explains FMEA as a key tool in RCM, helping to understand what can go wrong with equipment and plan maintenance strategies accordingly. It also highlights the importance of combining FMEA with criticality analysis to target the most significant failures.

💡Proactive Maintenance

Proactive maintenance focuses on designing and configuring equipment to minimize future maintenance needs. In the video, this approach is mentioned as a way to ensure equipment is easy to access and maintain from the start. It involves thinking ahead about potential problems and solutions even before equipment is put into operation.

💡Predictive Maintenance

Predictive maintenance involves using technology, such as infrared or vibration analysis, to monitor equipment while it’s in operation and predict when it might fail. This approach helps in addressing issues before they become serious. The video describes predictive maintenance as a key element in RCM, allowing organizations to detect early signs of failure that may not be visible or audible.

💡Enterprise Asset Management System (EAM)

An Enterprise Asset Management System (EAM) is software that helps track, plan, and manage maintenance activities, such as work orders and preventive maintenance routines. The video mentions EAM as an essential tool for implementing RCM, enabling organizations to efficiently schedule and track maintenance tasks, ensuring that recommendations from FMEA and criticality analysis are followed through.

💡Safety

Safety is a key consideration in reliability-centered maintenance, as discussed in the video. When performing criticality analysis, safety is identified as the top priority, especially in high-risk environments like refineries. The video uses the example of a refinery explosion to highlight the importance of considering safety risks in maintenance planning.

💡Redundancy

Redundancy refers to having backup systems or processes in place so that if one fails, another can take over without significant impact. The video explains that redundancy is a factor to consider in criticality analysis. Equipment or systems without redundancy are more critical because their failure can lead to larger disruptions, making them a priority for maintenance.

Highlights

Reliability-centered maintenance (RCM) is a world-class maintenance approach for process industries and manufacturing.

RCM optimizes all assets in a facility by using a combination of different maintenance strategies tailored to each system or equipment.

Preventive maintenance reduces unplanned repairs and lowers planned maintenance hours, but too much preventive maintenance can lead to failures and increased costs.

Reactive maintenance is fixing equipment after it breaks, which is inefficient and doesn’t consider costs.

Proactive maintenance assesses equipment before it’s operational to ensure ease of maintenance, sometimes even recommending replacement.

Predictive maintenance uses technologies like infrared, thermography, and lubrication analysis to detect issues that are invisible or inaudible to human senses.

Reliability-centered maintenance considers the appropriate maintenance strategy for each piece of equipment, including when to let equipment run to failure.

Criticality analysis is key in RCM, with safety being the top priority, followed by environmental, production stoppage, maintenance costs, system effects, and redundancy.

Failure modes and effects analysis (FMEA) identifies potential failure modes and their causes, and ranks them based on likelihood and impact.

FMEA helps establish recommended actions, such as maintaining lubrication to prevent bearing failures in compressors.

RCM implementation requires a cross-functional team, understanding current maintenance processes, setting goals, and tracking performance.

Enterprise Asset Management systems like ABB’s Service Pro streamline RCM implementation by managing preventive maintenance routines and criticality data.

Service Pro provides customers with benchmarking, comparing equipment performance at different sites to help identify potential improvements.

ABB’s advanced services, powered by Service Port, offer detailed data analysis and criticality insights for specific asset classes like control systems and drives.

RCM helps avoid costly mistakes, like the explosion at a refinery in Asia in 1992, which was caused by maintenance failures, including excessive preventive maintenance.

Transcripts

hello my name is Dave bureaus I'm a

global product marketing manager for ABB

process automation service and today

we're going to learn about an important

service concept called reliability

centered maintenance now why would we

want to learn about reliability centered

maintenance it's considered the

world-class maintenance approach for

process industries and manufacturing and

other industries as well so we're going

to cover three main areas in this

presentation it's just an overview but

those three main areas are equipment

criticality and analysis failure modes

and effects analysis on the equipment

and some basics about how to implement

reliability centered maintenance so

let's start with the definition of

reliability centered maintenance

reliability centered maintenance is a

high-level maintenance strategy that's

meant to optimize all the assets in the

facility and it uses a variety of

maintenance approaches to put together

an overall approach that's meaningful

for every different system or equipment

category and these maintenance

strategies are optimized to really

provide the most overall efficient

functioning of the plant so the notion

of preventive maintenance is that the

more preventive maintenance we do as you

can see here in this line is curving up

these bars that curve up here then the

fewer unplanned maintenance activities

will be required

those are breaking fixed emergency

repairs what also happens the more

preventive maintenance that we do the

actual planned maintenance hours also

come down we're just doing things more

effectively and we see cost benefits

across the board but what if we do too

much preventive maintenance is that

possible it is possible there's a sweet

spot where we only want to do the right

kind of maintenance at the right time if

we touch the equipment too much we can

actually induce failures that are costly

or we can just spend too much time

maintaining equipment and the actual

cost will beginning to creep up so we

want to be right here in this sweet spot

so what did we have before

reliability-centered maintenance well

first of all we had reactive maintenance

something breaks and we go and fix it

the idea is to get that equipment back

up as quickly as possible there's no

real preventive maintenance with that

approach costs aren't really considered

that carefully it's popular because it's

very easy to deploy something breaks and

we go fix it it's very in effect it's a

very inefficient use of manpower and

capital well we've already discussed

preventive maintenance of course that's

the next step if we can address

something that might break on a piece of

equipment before it breaks then we're

step ahead of the game

but as I also said it's possible to do

too much preventive maintenance we don't

want to do too much but still that's a

step in the right direction and it's

usually time directed we do it on a

regular basis every six weeks we're

going to lubricate a piece of machinery

then we go to proactive maintenance this

is the notion of looking at a production

line or a piece of equipment even before

it's put into operation and make sure

that it's easy to access to maintain or

to look at equipment say is that

equipment is that piece of equipment

easy to maintain should we replace that

equipment or if you're building a plant

or building a new line you can have that

as a criteria of looking at new

equipment as this equipment easy to

maintain that's proactive maintenance

there's also predictive maintenance this

is when we use a variety of technologies

such as infrared or thermography or

lubrication analysis different kinds of

technology to assess a piece of

equipment even while it's in operation

that might be able to determine certain

things on that piece of equipment that

we can't see with our naked eye or we

can't hear that will alert us hey

something needs to be addressed here

then finally we get to reliability

centered maintenance and as I mentioned

before reliability centered maintenance

takes advantages advantage of all of

those things and only chooses the right

approach for the right piece of

equipment even reactive maintenance or a

strategy might be to not choose any

maintenance approach at all all right

strategy might be to just let a piece of

equipment run the failure if it's

low-cost and you have a hot spare maybe

it's just too costly to try to touch

that on a regular basis let it feel

alright so let's talk about the three

main steps to effective

reliability-centered maintenance the

first one is to make sure that you

preserve equipment functionality by

establishing criticality levels of the

equipment the second was to is to

identify and prioritize failure modes

once we understand what the equipment

criticality is then we can start looking

at what's likely to fail on this piece

of equipment and put together some plans

to address it and then thirdly implement

reliability centered maintenance by

choosing the correct approaches

so for criticality let me just state

this clearly the first consideration for

criticality should always be safety here

we have an example of a refinery in Asia

I won't name the country that exploded

in 1992 and the explosion killed a

number of people and injured many more

when the analysis was done on why the

explosion occurred it was determined

that it was really a maintenance failure

you see there some of the reasons for

why repeated ratcheting reducing

diameter of a gasket retainer well I'm

not that familiar with this case but

repeated ratcheting that could be an

example of too much preventive

maintenance so the right maintenance

approaches weren't taken here and it led

to a disaster so as I said safety is

always number one when you're putting

together criticality analysis

environmental is up there in the same

level of safety the next consideration

is production stoppage if you're not

making product you're not making money

the third one is the maintenance expense

how costly is it to repair a certain

piece of equipment the fourth is the

effect on the systems remember systems

is a collection of equipment so what is

the effect if something breaks here what

kind of effect will a ripple effect will

have on other pieces of equipment it

could be a big effect so take that into

consideration and fifth redundancy does

this production or is this process have

some redundant features so that if it

fails in one area it

except in another area that's lacking

redundancy then it could be a higher

level of criticality we put those

criticality Xin to certain levels so

this is an example of criticality level

number one first of all if a failure

occurred here then it could result in a

loss of life or would high likelihood of

resulting in loss of life or limb or

permanent disability high likelihood of

an environmental emission high

likelihood of a very costly impact on

production and high likelihood of a

costly equipment repair maybe there's no

redundancy with that system so that

would get a criticality level number one

we just go down there criticality level

number two might be a measurable impact

on safety and environmental or or a less

costly impact production or a less

costly maintenance you get the idea

level three just a potential still

something to watch out for but not high

likelihood and then number four no

safety effects no environmental effects

no impact on production very minimal

minimal maintenance cost and maybe

there's multiple redundancy and in this

loved one so you just don't have to

worry that much about it so those are

criticality levels and before we can

assign criticality we need to establish

the systems systems is a group of

components and equipment category piece

of equipment and all the sub components

or it could just be one singular complex

piece of equipment here's an example

we'd have a major system with major sub

major assemblies major sub assemblies

components and we get down to a part

level for example a compressed air

system we'd have compressor assemblies

compressor units each compressor unit

would have a motor or compressor and

controls and then you get down to a

parts level with a motor so we I want to

identify all the major components of a

system group them together if we can

just do in a sensible fashion

so for instance we would have with that

same kind of example we would have and

our failure modes and effects analysis

worksheet we'd have the compressed air

system looking at the subsystem of air

compressor assembly and the components

would be compressor motor and valve then

we want to identify the failure modes

what could go wrong with each of those

components so that for a compressor for

instance it might seize and that would

be a failure for motor might fail to

start failure valve fails to close

failure next we want to look at the

failure mechanisms what would cause

these things to fail here's just some

examples could be corrosion or erosion

or a part fails or it's not calibrated

so forth so again in our example with a

compressor the failure mode is that it

seizes and what would cause that might

be a bearing failure so we just go

through all of our systems like that and

fill out this sheet and we create a

likelihood table of that happening with

a level such as this remote very low low

high up to extreme we also want and

effects descriptions so if we think

about the levels that we defined earlier

when we were talking about levels of

criticality a level one criticality

would be loss of life body part or

lost-time accident and so forth so we

want to identify those specifically

because we want to apply we want to have

an apples-to-apples comparison with all

the systems in the plant so again back

to our example we have with a compressor

we have the likelihood of it happening

as ranked high and we also have the

failure effect also ranked I would have

a major impact on production then we

want to put together the actions that we

would take if there were a failure so we

put together a list of recommendations

if a compressor ceases as a result of a

bearing failure we know that that's high

likelihood and also high negative impact

on production so the recommended action

is to maintain lubrication so that was

just a very cursory overview of what

criticality analysis

failure mode and effect analysis is now

we'll talk briefly about how a plant

would actually implement

reliability-centered maintenance first

of all you want to make sure you have a

team a cross-functional team you would

have that included mechanical

maintenance instrumentation electrical

maintenance process control operations

systems or plant engineering and perhaps

a facilitator you want to understand

your current maintenance processes after

you've done that criticality analysis

and the failure mode and effect analysis

you might have identified areas where

your processes just wouldn't allow you

to really effectively act on the

recommendations that you just put

together as part of the failure modes

and effects analysis you want to put

together a plan then to address those

areas that might be weaknesses in your

processes

start by setting goals what we really

want to do here do we want to increase

production what are the plants business

goals are we starting up a new line and

so we want to get it right the first

time

do we need to reduce maintenance costs

put together your approach how are you

going to track it how are you going to

who's going to be responsible for what

make sure that people know that they're

accountable so there's a name for

certain action so it doesn't fall into

the cracks finally implement into an

enterprise asset management system also

known as a computerized maintenance

management system this is software that

where work orders can be implemented and

the preventive maintenance routines can

be in there and the planning and

scheduling can be done there and all the

things that we've just discussed can all

be implemented in there and it expedites

effective implementation of

reliability-centered maintenance now ABB

has its own computerized maintenance

management system for ABB equipment and

that's called service Pro but service

Pro is uniquely designed for ABB use for

ABB equipment and processes and it comes

already with a hierarchy of systems and

subsystems and components that you see

here it also comes with the preventive

maintenance routines already embedded in

there so those things that we saw that

our result of a failure

and effects analysis many of those

things are already embedded in the

service Pro for many ABB asset classes

service Pro is also very helpful for

customers and doing their criticality

analysis what you see here is an

analysis of the service events and the

number of hours spent maintaining

specific pieces of equipment you see

here that analyzer 1200 has had a high

number of service instances and also a

high amount of service hours well that

will tell the customer perhaps it's a

critical piece of equipment that we need

to put in a different level a higher

level of criticality or maybe that's a

piece of equipment that needs to be

addressed or redesigned or even replaced

service Pro also provides benchmarking

for specific pieces of equipment at

other sites around the world that had

that same kind of that same piece of

equipment since service Pro is used by

ABB engineers and customers at hundreds

of sites all over the world a customer

can look at this kind of data and see

the piece of equipment my plant needs

more repair than that same piece of

equipment at many other customer sites

is there something wrong with the way

I'm maintaining it does that piece of

equipment need to be replaced all of

this is an important contribution to a

criticality analysis and failure modes

and effects analysis another tool that

ABB has that will help customers very

much and doing a criticality analysis

and a failure modes and effects analysis

as part of a reliability centered

maintenance implementation is advanced

services powered by service port as many

of you know and we deliver advanced

services we are gathering lots of data

and analyzing that data and identifying

categorizing and prioritizing things

that need to be addressed the same thing

that happens in a failure modes and

effects analysis here is a typical

screen that you'd see in a fingerprint

report or on the service port itself

that would show the systems or

subsystems or components that we are

monitoring or gathering data from with

the advanced service and with this size

bar we see

events that might indicate that that

piece of equipment needs to be looked at

more closely or that component needs to

be looked at more closely so again that

would be a great contributor to a

customer undertaking

reliability-centered maintenance program

we'd love to be able to provide that

that kind of analysis for customers for

all of their systems right now we only

offer them for certain important abb

asset classes we provide that kind of

analysis via advanced services powered

by service port for the Harmony control

system system 800 XA LV drives mine

hoists and quality control systems for

the paper industry so that's just a

brief overview of reliability centered

maintenance thank you for your time

you