Maintenance Management Loop FMEAFMECA Failure Mode Criticality and Effects Analysis A Failure Mode and Effects Analysis is often the first step in a systems reliability study It involves reviewing as many components assemblies and subsystems as possible to identify possible failure modes a ID: 489554
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Maintenance managementSlide2
Maintenance Management LoopSlide3
FMEA/FMECA
Failure Mode, (Criticality) and Effects Analysis
A Failure Mode and Effects Analysis is often the first step in a systems reliability study
It involves reviewing as many components, assemblies and subsystems as possible to identify possible failure modes and the causes and effects of such failuresFor each component, the failure modes and their resulting effects on the rest of the system are written onto a specific FMCEA form FMECA is an important element of RCMSlide4
Maintenance and inspection types and intervals
The main objective of this step is to determine the type and frequencies of maintenance and inspection tasks
In principle each failure mode/failure cause in the FMECA should be combated by a maintenance task
The RCM logic of an RCM analysis will be a starting point for identifying relevant maintenance tasksTo determine optimal frequencies of maintenance tasks it is usually required to establish a cost model to optimizeSlide5
Grouping of maintenance and inspection work
When the maintenance tasks are identified, and frequencies set it will usually be natural to group these activities into maintenance packages, each package describing what to do, and when to do it
It is a challenge to establish such an optimal grouping strategy
Why groupingSave “set-up” costConvenienceSlide6
Maintenance and inspection plan
A maintenance program shall be established, which includes written procedures for maintaining, testing, and repairing the various components
Such a program is often implemented by a computerized maintenance management system (CMMS)
A main task of the CMMS is to manage all work orders for preventive maintenance Slide7
Failures need corrective maintenance
Failures represent technical component failures (e.g. rail breakage, defect breaks etc), and deviations (e.g. geometrical deviations of the track)
Failures and deviations require repair, overhaul etc
Typically a work order for corrective maintenance (CM) is issuedThe CMMS will also manage these work orders Slide8
Reporting of result from maintenance and inspection
All maintenance work (functional testing, preventive maintenance, and corrective maintenance) shall be reported into an electronic maintenance database
The information to report depends on the type of maintenance work
Important information to reportExact description of failed/maintained unitFailure mode (CM)Component state (PM)
Failure cause (CM)Effect of failure (CM)Direct cost of maintenance actionSlide9
Database
The database used in the maintenance management loop is a conceptual term
A RAMS database may be realized as a part of the CMMS
It is essential that the database system contains necessary information for a proper data analysis Slide10
Data analysis and improvement analysis
A proper failure cause analysis (FCA), or root cause analysis (RCA)
Investigation into the failure reports to identify common cause problems (CCF)
Updated reliability data that was used in quantitative risk analyses/maintenance optimization modelsVerification of assumption related to safety critical functions/safety barriersSlide11
Restrictions
When maintenance comes out of control (large backlog) it is important to initiate operational restrictions
Closing a railway line
Reducing speedStop productionUse of compensating measuresRestrictions will also be necessary when the system integrity is threatened by weather conditions such as rain, frost, snow, high temperature etc. Slide12
Exercise
What is meant by “the maintenance management loop is NOT closed”