ABB - Reliability-Centered Maintenance
Summary
TLDRThis 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
🔧 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.
⚠️ 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.
📊 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.
🏭 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.
Mindmap
Keywords
💡Reliability Centered Maintenance (RCM)
💡Preventive Maintenance
💡Reactive Maintenance
💡Criticality Analysis
💡Failure Modes and Effects Analysis (FMEA)
💡Proactive Maintenance
💡Predictive Maintenance
💡Enterprise Asset Management System (EAM)
💡Safety
💡Redundancy
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
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