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 Duration 35 hours

Course Outline

Module 1: Foundational Context

  • Overview and Introduction
  • Historical Development of Reliability Centered Maintenance
  • Comparative Analysis of RCM II and RCM (Potential RCM III)
  • Strategic Objectives of Reliability Centered Maintenance
  • Categorization of Maintenance Strategies
  • Standardization Protocols and Standard Operating Procedures

Module 2: Performance Measurement: Key Performance Indicators (KPIs)

  • Selection Criteria for Key Performance Indicators
  • Guidelines for Metric Implementation
  • Illustrative Examples
  • Maintenance and Publication of Tracking Data
  • Specific RCM Metrics

Module 3: Analysis of Failure Mechanisms

  • Definition of Failure
  • System Definitions and Boundary Determination
  • Functional Requirements and Functional Failures
  • Identification of Failure Modes
  • Characteristics of Failures
  • Strategies for Failure Prevention

Module 4: RCM Foundations: Root Cause Analysis (RCA)

  • Differentiating Chronic vs. Sporadic Issues
  • Purpose and Application of RCFA
  • Seven Standard Steps in RCFA
  • Methodologies for Failure Analysis
  • FMEA Procedure – Core Component of Maintenance Management
  • Ishikawa Diagrams
  • Fault Tree Analysis
  • Pareto Charts

Module 5: RCM Process Integration with LEAN Management

  • Process Definitions and Fundamental Analysis
  • SIPOC and Value Stream Mapping
  • Identification of Process Waste
  • Waste Classification using the DOWNTIME Tool
  • Basic Process Improvement via ECRSA
  • LEAN Visual Environment – Implementation of 5S Methodology
  • Poka-Yoka Application for Error Prevention
  • Muda, Mura, and Muri Concepts
  • Construction of RCM Processes
  • RCM Decision Diagrams
  • Implementation of RCM Recommendations

Module 6: Supplementary RCM Program Elements

  • Statistical Applications in Maintenance
  • Precision Rebuild and Installation Procedures
  • Analysis of Failed Components
  • Rebuild Certification and Verification
  • Recurrence Control Measures
  • Introduction to SAE JA1011 and JA1012 Standards

Module 7: Practical Application: Maintenance Planning & Scheduling

  • Workload Assessment
  • Planning Principles
  • Scheduling Principles
  • Periodic Maintenance Scheduling (Daily, Weekly, and Other Cycles)

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