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DISTRIBUTION A. Approved for public release: distribution unlimited. 11
USMC Reliability Centered
MaintenanceVersion 1 / Feb 25, 2015
Mr. Del BennieMarine Corps Systems CommandAcquisition Logistics and Product Support (ALPS)Research and Readiness Analysis Team
DISTRIBUTION A. Approved for public release: distribution unlimited. 22
Agenda
• USMC Policy / MCSC draft RCM Order • MCSC RCM Proposed Integration• MCSC RCM Analysis Process/Execution• Recent and Pending RCM analyses• Notable Analysis Recommendations• DST/RCM/M&S Integration • Ongoing Challenges• Recap• Question and Answer period
DISTRIBUTION A. Approved for public release: distribution unlimited. 33
USMC RCM Policy
• MCO 4790.25 Ground Equipment Maintenance Program– Promulgated 12 Jan 2014– Officially task MCSC to conduct RCM
Per MCO 4790.25 (GEMP) Commander, Marine Corps Systems Command (MARCORSYSCOM)/Program Executive Office (PEO) As the Marine Corps ground equipment asset (Class VII PEI) life cycle manager, develop, implement, document, assess, and refine program/product management strategies and maintenance support plans throughout materiel life cycle through RCM analysis to support CBM+ concepts and the performance of maintenance within a TPM strategy.
• MCSC draft interim RCM Order– Currently being routed to the various competencies prior to presentation to the
Commander and Program Executive Officer Land Systems for concurrence and signature
– The order is planned to be subsumed by the MCSC Maintenance Planning and Management policy
DISTRIBUTION A. Approved for public release: distribution unlimited. 44
IOCBA
TechnologyMaturation & Risk
Reduction
Engineering & Manufacturing Development
Production & Deployment
Systems Acquisition
Operations & Support
C
Sustainment
FRPDecisionReview
FOC
LRIP/IOT&ECDR
Pre-Systems Acquisition
MaterielSolutionAnalysis
ConceptDecision
PDR
Proposed Integration (draft)
(DOD 5000)
RCM Analysis
(Proposed)
RCM Analysis/Update
(every 3 - 5 years)
(Proposed)
RCM Analysis/Update*
* other potential trigger events
(Proposed)
RCM/Functional Analysis
(Proposed)
RCM Analysis/Update
(or as required)
1 2 3 4 5 6 6 6 6 6PoPSGates
Draft Process
DISTRIBUTION A. Approved for public release: distribution unlimited. 55
Proposed Integration (draft)
IOCBA
TMRR E&MD Prod & Depl O&S
C
FRPDR
FOC
CDR
MSA
PDR
Early Functional Analysis
• Chaired by Requirements Developer, supported by MCSC• Defines System Functions and Functional Failures (performance parameters)• Refines common understanding of operating context• Supports AoA activities and Alternate System Review (ASR)• Supports refinement of ICD, Draft CDD and follow on RFPs
5
DISTRIBUTION A. Approved for public release: distribution unlimited. 66
Proposed Integration (draft)
IOCBA
TMRR E&MD Prod & Depl O&S
C
FRPDR
FOC
CDR
MSA
PDR
Pre MS B RCM Analysis
• Chaired by MCSC (as are the remainder of the analyses)• Initial FMECA, MTL/PMCS and system training developed (cursory knowledge of CIs)• Best opportunity to recommend design changes that will enhance reliability prior to establishment of allocated baseline• Supports refinement of Draft CDD, including Sustainment KPP and Reliability and Ownership Cost KSAs as well as follow on RFPs
6
DISTRIBUTION A. Approved for public release: distribution unlimited. 77
Proposed Integration (draft)
IOCBA
TMRR E&MD Prod & Depl O&S
C
FRPDR
FOC
CDR
MSA
PDR
Pre CDR RCM Analysis/Update
• Refined FMECA, MTL and system training based on proposed configuration baseline (matured knowledge of CIs)• Refined PMCS schedule and training to support Product Support Demos and additional DT/OT/FUE/OA events• Supports refinement of CPD (Sustainment KPP, Reliability and Ownership Cost KSAs) as well as follow on RFPs• Out of all of the pre-fielding analyses, this is the most critical due to the fidelity of system design information.
7
DISTRIBUTION A. Approved for public release: distribution unlimited. 88
Proposed Integration (draft)
IOCBA
TMRR E&MD Prod & Depl O&S
C
FRPDR
FOC
CDR
MSA
PDR
Post MS-C RCM Analysis/Update
• Considers results of product support demonstrations and Operational Tests/Field User Evaluations/Operator Assessments• Final refinement to overarching product support strategy, MTL, PMCS schedule, TMs, system training and related products prior to full rate production and fielding.
8
DISTRIBUTION A. Approved for public release: distribution unlimited. 99
Proposed Integration (draft)
IOCBA
TMRR E&MD Prod & Depl O&S
C
FRPDR
FOC
CDR
MSA
PDR
Iterative RCM Analyses/Updates
• Every 3 – 5 years, or trigger event • Captures updated configurations/ECPs• Addresses observed failure trends• Updates MTL/PMCS schedule as more system performance and reliability information becomes available• Provides feedback loop to the Warfighter and to theRequirements developers for similar/replacement systems
9
DISTRIBUTION A. Approved for public release: distribution unlimited. 1010
MCSC RCM Analyses Process
Research & Readiness Analysis
ALPS & Program
Office
Program Office
LEGEND
MCSC RCM ProcessV5.0 09/26/14Analysis
Requested
1Requirement
Validated
2Establish
Objectives & Boundary
3Failure Mode
Estimate
4 5Analysis
Approved
RCM Review Group
Requirements/ Responsibilities
6
A
A
Yes
No
Technical Documentation
8Release of
Naval Message
7Development of Operating
Context
10
Documentation Review
9
Review Group Read Ahead
11
Confirmation brief
12
B
II- Analysis RequirementsI- Analysis Determination
III- Analysis Planning
Orientation/ Group Training
13
BPhase 1:
Information Phase
14
Consensus on Decisions
16
Yes
No
C C
DPhase 2: Decision
Phase
15
IV- RCM Analysis
Provide ILA Documentation
D Technical Audit
18
Technically Correct
19
No
C
Min. 60 Days prior to IV
Publish Updated Analysis
21
22
Recommendations Approved
Yes
Yes
No
Implement Recommendations
23
Record Disapproval
Rationale
25A Living Program
Analysis Complete
17
RCMA
V- Audit Phase
Assignment to Logistics (PMCS, Tech
manual, Training, process), Engineer
(Design) IPT
24
SUSTAIN- Emergent Issues- Age Exploration- Hardware Changes - Trend/degrader analysis- Document Reviews
E
E
VI- Implementation Phase
Management Audit
20
Provide Feedback to R2A
26
180-240 Days
DISTRIBUTION A. Approved for public release: distribution unlimited. 1111
Marine MaintainerMarine
Operator
EngineerProgram Office
rep(s)
SMEs as requiredHFE
SafetyEnvironmentalThermal Engr
Etc.
Task Organized
RCM ReviewGroup
Trained RCM Facilitator
RCM Analyses Task Organized Review Group
DISTRIBUTION A. Approved for public release: distribution unlimited. 1212
Recent/Pending RCM Analyses
Expeditionary Field Kitchen (EFK) Airtronic Burner Multi-Band Radio II FoS (MBR II) Blue Force Tracker FoS (BFT) MK970 Refueler Assault Amphibious Vehicle (AAV) Subsystems:
– AAV P7A1 Hull PMCS– AAV Family Of Vehicles Deadline Criteria– Water Propulsion & Steering Systems– AAV Hydraulic System– AAV Upgunned Weapon Station PMCS– AAV Transmission/Suspension Analysis– AAV Engine/ Fuel Systems– AAV Upgunned WS– AAV Hull electrical/ AFSSS
Logistics Vehicle System Replacement (LVSR) – Steering/Suspension– Engine/Fuel/Air/Exhaust/Cooling– Drive Train/Transmission/Axle/Transfer– Hydraulics Fans/LHS, Winch– Air and Electrical System, CTIS, Backfit, and
Storage Medium Tactical Vehicle Replacement (MTVR)
MK 154 Mine Clearance Launcher AN/TPS-80 Ground/Air Task Oriented Radar M9 Armored Combat Earthmover
RECENT PENDING
DISTRIBUTION A. Approved for public release: distribution unlimited. 1313
Program Analysis Recommendations
Assault Amphibious Vehicle (AAV) PMCS
Recommended the reduction of 70% of the PMCS tasks on the AAV platform
Assault Amphibious Vehicle (AAV) Deadline Criteria
Recommended that operational checklists include new columns for deadline criteria and exceptions to non-use
Multi-Band Radio II (MBR II)Recommended development of a mitigation strategy for HUB battery removal (bricking)
Airtronic BurnerRecommended the transition to full organic support at significant cost savings to the USMC
Expeditionary Field Kitchen (EFK)Recommended the reevaluation of the upper temperature operating limit contained in MIL STD 810G (120 degrees F)
Blue Force Tracker (BFT)
Recommendation to investigate a possible redesign to incorporate a software change. If this software change and other recommendations were to be incorporated, the projected 10-year cost decrease to the BFT FoS would reflect a decrease of $464,773 in material costs and a net decrease of 4,863,072 maintenance man-hours at all maintenance levels.
Notable Analysis Recommendations
DISTRIBUTION A. Approved for public release: distribution unlimited. 1414
RCM
SOEDST
M&S
• Predictive Modeling & Simulation applies advanced simulation technology to identify significant return on investment and to resolve asset management challenges.
Pending Initiative• ALPS intends to provide Program Managers within MCSC and PEO LS with synergized RCM, failure analysis and predictive modeling and simulation (M&S) capabilities. This will enable Product Support decisions that maximize readiness and minimize cost.
RCM / SOE DST / M&S Integration
DISTRIBUTION A. Approved for public release: distribution unlimited. 1515
RCM
SOEDST
M&S
• RCM defines what must be done to a system to achieve the desired levels of safety, reliability, environmental soundness, and operational readiness, at best cost (DODI 4151.22). MCSC is currently conducting Reliability Centered Analyses utilizing a stand alone RCM approach however, efforts are underway to integrate the following analysis tools to further realize the benefits and power of RCM:
• Systems Operational Effectiveness Decision Support Tool (SOE DST) The SOE DST is a web based application which utilizes
USMC data stored in the MDR in order to provide reliability and lifecycle trend analysis
• What has happened / is happening
• M&S / DEMAND Pro Is a high-resolution modeling and simulation tool that enables detailed
lifecycle predictions and quantifies risk & uncertainty• What should/can happen
Integration & Opportunities: Analysis Tools
DISTRIBUTION A. Approved for public release: distribution unlimited. 1616
AAV RCM / Modeling & Simulation Integration
- AAV FoV Analysis completed in February 2014- AAV PMCS Modeling & Simulation Analysis September 2013
- Objectives:• Evaluate the current impact of the RCM derived PMCS
recommendations• Evaluate reliability changes due to RCM implementation• Construct and evaluate a high-resolution simulation to assess the
long-term impact of RCM derived PMCS modifications.• Recommend possible modifications to RCM derived PMCS
recommendations
- MetricsPerformance of each alternative is evaluated with five primary metrics
- Cost- Corrective Maintenance - Operational Availability (AO) - Mean Down Time (MDT)- Materiel Availability (AM)
RCM
SOEDST
M&S
DISTRIBUTION A. Approved for public release: distribution unlimited. 1717
RCM Five Year Comparison
17
Pre Post DAchieved Availability 64.5% 71.0% +6.4%Materiel Availability 95.6% 96.9% +1.4%Achieved Hours 531 k 539 k +1.4% (7,500 hrs)PMCS Man Hours 65.4 k 20.3 k –69%Corrective Man Hours 1.64 M 1.67 M +2.0%Parts Cost $76.5 M $77.5 M +1.3%Mean Down Time 38.3 Days 26.2 Days –32%
Pre-RCM• 11 checklists• 64:03:12 hours total if each
checklist performed once• Many redundant tasks • Limited compliance
– “Rainbow” Sheets: daily check of 68 tasks broken into groups, performed over 4-week period
Post-RCM• 15 checklists• 19:37:53 hours total if each
checklist performed once• Greatly reduced redundancy• Greater compliance• Eliminate unnecessary tasks• Deadline criteria clearly defined
DISTRIBUTION A. Approved for public release: distribution unlimited. 1818
• Ongoing Challenges– Non-compliant RCM deliverables (SAE JA1011) – Implementation of recommendations by PMOs– Low demand signal– Misunderstanding of what RCM achieves– Accurate Failure Mode data– SME support
DISTRIBUTION A. Approved for public release: distribution unlimited. 1919
What's wrong?
A design FMEA/FMECA is not synonymous with an RCM FMEA/FMECA
ITEMFUNCTION
FAILURE MODE
CAUSE OPFAILURE EFFECT
TITLE MODE LOCAL NEXT HIGHER END EFFECTS DED 180 DED 128 DED 124 DED 247 DED 126 DED 127 DED 125
001 : Rod End To provide a pivot point for the Balancer. To provide a fixing point for the Rod (item 102).
Structural failure Fatigue Firing/ Emplacement/ Displacement
Rod becomes detached. Piston forced against Cylinder Eye.
Loss of Balancer structural integrity. Cradle may become distorted. Minor instability results in potential minor injury.
Unable to elevate or depress cannon. Stop firing.
002 : Gland To provide a housing for the seals and wear rings (items 204, 205, 206, 207 & 208). To cap the end of the Cylinder (item 101).
Structural failure Fatigue Firing/ Emplacement/ Displacement
Leakage of N2 to atmosphere. No pressure in the system.
No pressure to counterbalance the elevating mass.
Unable to elevate or depress cannon. Stop firing.
The identified function's are the functions of the piece parts and not that of the assetunder review required by RCM
The remaining analysis information is based on preventing the loss of function of the piece parts instead of the asset under review. This leads to a maintenance strategy that does not support the tenets of RCM and therefore cannot be labeled RCM
This is an excerpt of one of many contract RCM deliverables tech audited by AC ALPS RCM personnel. This has been a common theme throughout.
DISTRIBUTION A. Approved for public release: distribution unlimited. 2020
Recap
• USMC Policy/MCSC Draft RCM Order • MCSC RCM Proposed Integration• MCSC RCM Analysis Process/Execution• Recent and Pending RCM Analyses• Notable Analysis Recommendations• DST/RCM/M&S Integration • Ongoing Challenges• Question and Answer Period
DISTRIBUTION A. Approved for public release: distribution unlimited. 2121
Maj. Dustin Thorn703-432-4022
Mr. Del Bennie703-432-3525
Captain Chris Radel703-432-3524
Mr. Herbie Morris703-432-4050
Any Questions?
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Backup Slides
Backup Slides
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• RCM ISO Depot Maintenance– Briefed Commander MARCORLOGCOM