20160704 rv presentation rca versus rcm
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Introduction
2008 2000 1995 1990
Loopbaan
Ir. Ron Vonk
Partner, senior facilitator & trainer bij CoThink
Why this presentation?
RCM?
RCA?
RCM &
RCA?
Choices made between RCM and RCA prove
not always to be the best ones…
No satisfactory answer when the question is asked:
“Why focus on RCM?” or “Why focus on RCA?”
Content
1. Introduction RCM and RCA
2. Similarities and distinctions
3. Pros and cons
4. Choice between RCM and RCA
5. Conclusions & recommendations
Reliability Centred Maintenance (RCM)
Best practice to determine and optimize a maintenance
program for equipments, to maximize availability for
minimum costs, taking into account all requirements set
in advance
Reliability Centred Maintenance (Wikipedia)
Failure Mode Effect & Criticality Analysis (FMECA)
RCM2 Failure Mode & Effect Analyse (FMEA)
Asset Performance Management Concept (APMC)
Dynamic RCM …. Streamlined RCM
Variants of RCM
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Root Cause Analysis (RCA)
A class of problem solving methods aimed at identifying
the root causes of problems or events, in which a root
cause is used to describe the depth in the causal chain
where an intervention could reasonably be implemented
to change performance and prevent an undesirable
outcome.
Root Cause Analysis (Wikipedia)
RCA approaches
(approaches for continuous
improvement
RCA methods
RATIO
DMAIC
8D
A3
Kaizen SCOPE
….
Event Mapping
Ishikawa Diagram
5 Why
Problem Analysis
Current Reality Tree
Tripod
Barrier analysis
… Apollo
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Content
1. Introduction RCM and RCA
2. Similarities and distinctions
3. Pros and cons
4. Choice between RCM and RCA
5. Conclusions & recommendations
RCM process
RCA process
Similarities RCM and RCA
Method (how) Input Output
Asset/Maintenance objectives
Asset/Maint. performances
Knowledge & experience
Documentation
Improvement proposals
- Preventive Maintenance
- Modifications
- Operation procedures
- ...
Use of methods (FMEA/FMECA/RCM2/…)
Team with facilitator
Use of software (Excel, Optimizer+, …)
Method (how) Input Output
Asset/Maintenance objectives
Asset/Maint. performances
Knowledge & experience
Documentation
Improvement proposals
- Preventive Maintenance
- Modifications
- Operation procedures
- ...
Use of methods (5Why, Event Mapping,..)
Team with facilitator
Use of software (Excel, Optimizer+, …)
Use of methods (FMEA/FMECA/RCM2/…)
Team with facilitator
Use of software (Excel, Optimizer+, …)
Use of methods (5Why, Event Mapping,..)
Team with facilitator
Use of software (Excel, Optimizer+, ...)
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Time Now
Methods to find root
causes, to solve and
prevent a problem that
actually occurred
Methods to prevent
unacceptable potential
problems
RCA RCM
Distinctions between RCM and RCA
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
RCM
RCA
Proactive Reactive
Mostly long during
interventions
Mostly short
interventions
Implementation of
improvement proposals
often difficult
- A lot of work
- Lack of buy-in/support
- Higher probility of budget
issues
Implementation of
improvement proporals
relatively easy
- Less work
- Strong buy-in/support
- Lower probability of
budget issues
Analyses quit often
“boring” (caused by
repetiveness)
Analyses mostly
“exciting” (different
every time)
Distinctions between RCM and RCA
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Content
1. Introduction RCM and RCA
2. Similarities and distinctions
3. Pros and cons
4. Choice between RCM and RCA
5. Conclusions & recommendations
RCM
RCA
Pros and cons RCM and RCA
Pros
Proactive, also potential problems
will be taken in consideration
during analysis
Development or improvement of
maintenance concept for total
equipment
Contribution to compliancy: being
able to demonstrate correct
preventive actions are in place
Pros
Costing less time and money
Rapid results
Less/no challenges to get or
maintain buy-in
Cons
Relatively costly in terms of
money and time
Results less visible on short
term
Obtain and maintain buy-in is
a challenge
Cons
Reactive: problem has already
occurred
Improvement of maintenance
concept (if applicable) only for
part of equipment: to prevent
reoccurance of specific failure
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Content
1. Introduction RCM and RCA
2. Similarities and distinctions
3. Pros and cons
4. Choice between RCM and RCA
5. Conclusions & recommendations
Why RCM or RCA? Bron: Mainnovation,
“VDM, New faith in maintenance”
RCM
RCA RCA
Application of RCM and RCA are recurring
steps in continuous improvement circle!
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Focus RCM better then RCA?
% costs
preventive
maintenance
Benchmark costs of preventive maintenance
As % of total maintenance costs
Organisations in benchmark
Biased preference
for prevention is
sometimes
obstinately!
Is that the reason
why there seems to
be a preference to
focus on RCM
instead of RCA?
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
If we need to decide between Preventive or Corrective
Maintenance, we seem to be wise: we choose based on
risk and minimum total costs
Probability
Seriousness
of
effect
Acceptable
Corrective
measures
Not acceptable
Preventive
measures
Risk = Probability x Seriousness
Costs
preventive
maintenance
Total costs
Why should we do it differently when choosing
between RCM and RCA?
€
Level of preventive maintenance
Costs corrective
maintenance +
downtime costs
Minimum total costs
Focus RCM better then RCA?
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Focus on RCM or RCA?
Big failure, incident
or accident
RCA
Asset/Maintenance objectives
Asset/Maint. Performance
Knowledge & Experience
Documentation
Quick FMECA
Equipment (still)
critical?
No Yes
RCA** RCM
** RCA based on “cost drivers” and “performance killers”
Current
maintenance
concept *
* If there is not (yet) a compliancy issue. Otherwise, start from scretch.
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
Content
1. Introduction RCM and RCA
2. Similarities and distinctions
3. Pros and cons
4. Choice between RCM and RCA
5. Conclusions & recommendations
Conclusions & recommendations
Adding value with RCM or RCA?
It is not “RCM or RCA?”, it should be “RCM and RCA!”
In any case of big failures or incidents: always apply RCA.
Define clear “triggers” though: What is big?
Is compliancy an issue? Apply RCM for critical equipment,
starting with “If we won’t do any maintenance…”
Is compliancy not an issue? Apply RCM for equipment
which are still critical, regardless the current maintenance
concept (where there are still unacceptable risks)
For non-critical equipments: focus with RCA on elimination
of “cost drivers” and “performance killers”!
Introduction RCM
en RCA
Similarities and
disctinctions
Pros and cons
Choice between
RCM and RCA
Conclusions &
recommendations
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