1
Maintenance Methodologies and
History
Presented By:
Tim Bair & Jeff Banks
Research Engineers
The Applied Research Laboratory at
The Pennsylvania State University
Welcome to the CBM & RCM
“Short Course”
2
Course Summary
• Introductions
• ARL Overview
• Class experience poll
• Course Overview
• Maintenance History
• Intro to CBM and RCM
• RCM Overview
• FMECA
• CBM Overview
• CBM examples
• Course Wrap-up/Feedback
3
Biography: Tim Bair
• B.S. The Pennsylvania State University
• MS. Air Force Institute of Technology
• MS Industrial College of the Armed Forces
• Colonel, USAF (Ret)– Aircraft Maintenance/Logistics 26 years
– 13 assignments at flightline, numbered AF and HQ ACC, et al• Worked on F-16, A-10, F-15, F-4E, RF-4C, OV-10. F-106, T-33
• HQ ACC logistics lead for F-16 program
• Germany, Korea (2), AFROTC,
– Culminated as Dep. Director, Maintenance & Logistics, OO-ALC
• Current Work – Penn State Applied Research Lab – Director, Institute for Manufacturing and Sustainment Technologies
– iMAST is a Navy ManTech Center of Excellence
– Execute projects for NAVSEA, NAVAIR and MARCOR designed to save money in acquisition and life cycle cost
4
Biography: Jeffrey Banks
• B.S. Mechanical Engineering – Villanova University– Worked as an intern at the CCA Paper Mill in Philadelphia as an assistant to
the Chief Maintenance Engineer
• M.S. Acoustics – The Pennsylvania State University– Graduate work involved developing unique sensor fusion technology for
detecting gear, bearing and shaft faults in mechanical systems.
• Industry – Mead Paper Company– Worked as a Diagnostic Engineer at the Corporate R&D Facility.
– Responsibilities involved traveling to Mead Corporation divisions to conduct diagnostic surveys; primarily to troubleshoot machine maintenance and process variability issues related to paper making processes and converting operations.
– Specialization in analyzing vibration\pulsation issues that affected manufacturing concerns, maintenance issues and capitol expansion.
• Current Work – Penn State Applied Research Lab – Department head & research engineer duties include RCM, CBM and
developing machinery health monitoring systems/diagnostic and prognostic technology for asset health management.
5
“…maintains a special long-term strategic relationship with DoD for technology development and engineering applications.”
Established in 1945 by the Navy post WW II
Technology Areas
Materials & Mfr’ing S&T Comms and Information
Undersea Vehicles Power and Energy
Hydrodynamics and Structures Navigation
Acoustics & Quieting Undersea Weapons
Largest Interdisciplinary Research Unit at
Penn State – ~1200 faculty/engineers, staff,
students
Classified facilities and programs
Research Expenditures FY14 >$180M
Designated an University Affiliated Research
Center by DoD in 1996
•
•
•
•
•
•
•
•
We Are….
6
Serve as a university center of
research excellence and advanced
capabilities for critical DoD
sciences and technology and
related applications.
Champion the transition of
advanced technology to
operational systems in support of
DoD acquisition programs, legacy
platforms and the defense industry.
Contribute to the education,
research, and service mission of
The Pennsylvania State University
VIRGINIA CLASS
STUDENT PHOTO
ARL Mission
ARMORED AND TACTICAL VEHICLES
F-35 JOINT STRIKE FIGHTER
7
MISSION
To be the preeminent source of innovative technologies-materials, process,
manufacturing, design and logistics technologies for affordable, high
performance platform structures and systems.
Materials Processing Material Design and
Characterization
Process Development
Advanced Coatings
Advanced Composites Marine, Land, and
Aerospace Systems
– Design and Analysis
– Materials Char./Qual.
– Process Optimization
– NDE, Repair
Laser Processing Laser Physics
Process Technology
System Integration
Manufacturing Systems Automated Conceptual
Design/Trade Space Exploration
Simulation and Modeling for
Manufacturing
Shearography, Spectrometry,
Inspection, NDT
Environmental Technology
MAJOR PROGRAMSiMAST, Drivetrain Technology Center,
DTRA University Partnership,
Systems Operations & Automation
Condition Based Maintenance
Sense and Respond Logistics
Integrated Health Management
Materials and Manufacturing
Mission and Organization
9
Maintenance 101
1903
2014
1st Gen: Me 262
MiG 15, F-86
2nd Gen: onboard radar,
IR missile tech
3rd Gen: F-4, ^IR & radar systems,
air-air prime, grnd attack avionics,
4th Gen: ^ maneuver, fly-by-wire, digital
avionics buses, F-15, 16, 18
5th Gen: LO tech, hi-perf engines, F-35
10
Maintenance Methodologies
• All of these processes have a place. Operating Equipment Asset Management uses concepts and ideas from all four types of maintenance, assembled in a mix to best address safety, environmental, mission, business and site requirements.
Operating Equipment Asset Management by John Mitchell
11
Maintenance Methodologies
• All of these processes have a place. Operating Equipment Asset Management uses concepts and ideas from all four types of maintenance, assembled in a mix to best address safety, environmental, mission, business and site requirements.
Operating Equipment Asset Management by John Mitchell
12
Reactive Maintenance
• Reactive Maintenance is corrective action applied on failure or obvious, unanticipated threat of failure: run-to-failure.
– Run-to-failure is simplistic, requires no forethought, and, at least up to the point of equipment failure, appears to require the least support.
• Not recommended if an unexpected failure can endanger personnel; release toxic; flammable or polluting material; interrupt production; or cause collateral damage.
• Reactive maintenance does make economic sense in some cases (replacing easily accessible light bulbs, fuses) but the decision to implement reactive maintenance must be based on probability, cost, and consequences.
13
Maintenance Methodologies
• All of these processes have a place. Operating Equipment Asset Management uses concepts and ideas from all four types of maintenance, assembled in a mix to best address safety, environmental, mission, business and site requirements.
Operating Equipment Asset Management by John Mitchell
14
Preventive Maintenance (PM)
• Preventative Maintenance tasks include inspection, service and/or replacement conducted at regular, scheduled intervals.– Established to avoid failure
based on average statistical/anticipated lifetime.
• PM may be invasive, requiring an outage and disassembly for visual inspection and/or overhaul/replacement regardless of condition.
– The intervals between specific Preventive Maintenance tasks are based on average life, lead the fleet testing, scheduled Phase/ISO/PDM
• A PM program can be cost effective when equipment operation is consistent, average life is predictable within a reasonable span, failures are well understood, and useful failure statistics are available.
17
Maintenance Methodologies
• All of these processes have a place. Operating Equipment Asset Management uses concepts and ideas from all four types of maintenance, assembled in a mix to best address safety, environmental, mission, business and site requirements.
Operating Equipment Asset Management by John Mitchell
18
Condition Based Maintenance
1. Condition measurement consists of non-invasive measurements that define mechanical and operating condition
– Measurements may be made continuously (on-line) from installed transducers or periodically with portable equipment.
2. Condition monitoring and (health) assessment is the individual and collective comparison of condition measurements, value versus time trends to arrive at an appraisal of current condition, identify and analyze defects (diagnostics).
– Condition assessment is also directed at detecting and identifying degradation mechanisms.
3. Repair and Maintenance actions required as indicated by condition monitoring and health assessment—i.e. based on the objective evidence of need.
OPERATING EQUIPMENT ASSET MANAGEMENT YOUR 21ST CENTURY COMPETITIVE NECESSITY, By John S. Mitchell
19
Predictive (PdM) or Condition
Based Maintenance (CBM)
• PdM/CBM: Maintenance action based on actual condition obtained from in-situ, non-invasive tests, operating and condition measurements.– Condition Based Maintenance has proven capable of identifying
faults early enough to minimize the impact of:
• operational interruptions
• avoid expensive failures
• including collateral damage
• significantly reduce the cost of maintenance.
• Some potential failures, such as fatigue, are not easily detected with condition measurements.
20
Maintenance Methodologies
• All of these processes have a place. Operating Equipment Asset Management uses concepts and ideas from all four types of maintenance, assembled in a mix to best address safety, environmental, mission, business and site requirements.
Operating Equipment Asset Management by John Mitchell
21
Proactive Maintenance
• Proactive Maintenance (PCM): The collection of efforts to identify, monitor and control future failure with an emphasis on the understanding and elimination of the cause of failure.
• Proactive maintenance activities include:
– The development of design specifications to incorporate maintenance lessons learned and to ensure future maintainability and supportability.
– Performing root cause failure analysis to understand why in-service systems failed.
– The development of repair specifications to eliminate underlying causes of failure.
22
Cost of Different Maintenance
Methodologies
• A study conducted by the power generating industry in 1986, reported lifecycle cost savings for PM in the range of 12 to 18 percent compared to reactive maintenance.
• PM significantly reduces Operations and Maintenance (O&M) costs compared to operate-to-failure; however, costly unexpected failures may still occur when the span between average and minimum lifetime is large
23
Prognostics and Remaining
Useful Life (RUL)
• Currently, most CBM
technology provides
diagnostic information.
– Provides an indication of a
fault and a degree of
severity.
– Diagnostics does not
provide an accurate
indication of remaining
useful life of the equipment.
• Prognostics: is the ability to
accurately predict when a
component, system or
equipment will fail.
• A RUL prediction provides for the
most effective management of an
asset.
– Plan maintenance actions
– Get the most life out of equipment
25
Maintenance Methodology
Progression
• Over the years, industry, in general, has recognized that migrating from reactive or breakdown maintenance to condition-based maintenance has the dual advantage of increased effectiveness and decreased cost
Operating Equipment Asset Management by John Mitchell
26
Comprehensive Maintenance
• Practitioners recognize that a
comprehensive equipment
management strategy will
include a blend of:
– Reactive Maintenance
– Preventive Maintenance
– Condition-Based
Maintenance
– Proactive Maintenance
• To be applied based on the
specific circumstances,
probability, and consequences
(risk) of failure
27
CBM is coming to a flightline
near you!
• So what is DoD doing
about it?
• And when will I see it
28
DoD Initiative: CBM+
• CBM+ focuses on inserting technologies that improve
maintenance capabilities and processes into both new and
legacy weapon systems and integrates the support elements to
enable enhanced maintenance-centric logistics system
responses.
• CBM+ includes a conscious effort
to shift equipment maintenance
from an unscheduled, reactive
approach at the time of failure to
a more proactive and predictive
(CBM) approach that is driven by
condition sensing and integrated,
analysis-based decisions.
Reference: Condition Based Maintenance Plus DoD Guidebook, May 2008
29
CBM+ (per DAU)
• Condition-based maintenance (CBM+) can be defined as a
set of maintenance processes and capabilities derived, in
large part, from real-time assessment of weapon system
condition obtained from embedded sensors and/or external
tests and measurements using portable equipment. The
goal of CBM+ is to perform maintenance only upon
evidence of need. The desirable outcome of CBM+ is a
force of maintainers with knowledge, skill sets, and tools for
timely maintenance of complex systems through use of
technologies that improve maintenance decisions and
integrate the logistics processes.
30
CBM+ (per DAU)
• CBM+ focuses on inserting, into both new and legacy weapon systems, technology to
support improved maintenance capabilities and business processes. It also involves
integrating and changing business processes to dramatically improve logistics
system responsiveness. Under consideration are capabilities such as enhanced
Prognostics & Health Management (PHM) and Enhanced Diagnostics techniques,
failure trend analysis, electronic portable or point of maintenance aids, serial item
management, automatic identification technology and data-driven interactive
maintenance training. The ultimate intent of this initiative is to increase
operational availability and readiness throughout the weapon system life cycle at a
reduced cost. CBM+ will help predict a system's remaining operational life span,
support operator decision-making, interface with control systems, aid maintenance
repairs, and provide feedback to the logistics support and system design
communities. Specific Capabilities include:
· Enhanced prognostic and diagnostic techniques
· Failure trend analysis
· Electronic portable or point-of-maintenance aids
· Serial item management
· Automatic identification technology
· Data-driven interactive maintenance training
31
Air Force CBM+
• Condition Based Maintenance (CBM) utilizes real time
assessment of weapon system condition obtained from
embedded sensors and/or external test and
measurements using portable equipment.
– The goal of CBM is to perform maintenance only upon
evidence of need.
• “CBM+ expands upon these basic concepts by
encompassing other technologies, processes, and
procedures that enable improved maintenance and logistic
practices.”
Reference: Air Force Condition Based Maintenance + Fact Sheet
32
Air Force CBM+
• “Ten enabling technologies and concepts constitute the
initial Air Force baseline for achieving the DoD vision for
CBM+ implementation”:
– Prognostics
– Diagnostics
– Portable Maintenance Aid
– Interactive Electronic Technical Manuals
– Interactive Training
– Data Analysis
– Integrated Information Systems
– Automatic Identification Technology
– Reliability Centered Maintenance
– Joint Total Asset Visibility
Reference: Air Force Condition Based Maintenance + Fact Sheet
33
Condition Based Maintenance
Plus (CBM+)(from AFRL CBM+ Research Environment brief)
• DoDD 4151.18 – Maintenance of Military Materiel – Mar 2004
• AFI 63-107 – Integrated Product Support Planning and Assessment – Nov 2004
• DODI 4151.22 – CBM+ Policy – Dec 2007
• DoD CBM+ Guidebook – May 2008
. . . “ the application and integration of appropriate processes, technologies, and knowledge-based capabilities to improve the reliability and maintenance effectiveness of DoD systems and components.”
Polic
y &
Guid
ance
Form
al
Definitio
nA
F S
olu
tions
Develop &
Sustain
Warfighting
Systems
(D&SWS)
AF Transformation
Supply Chain
Operations
Systems Lifecycle Integrity Management (SLIM)
CBM+ (Prognostics
RUL, Diagnostics)
35
CBM+ for JSF
• CBM+ is supported by
automated
maintenance
information systems
that seamlessly
integrate with other
logistics systems.
• This leads to more
efficient maintenance,
better readiness, and
the cost savings
associated with
smaller logistics
footprints.Reference: Air Force Condition Based Maintenance + Fact Sheet
37
The RCM Process
• How to best design a maintenance management
strategy for your assets or platforms?
– Which methodologies will allow for the most effective
and efficient operation and maintenance of each asset.
• The Reliability Centered Maintenance process is
used to determine which type or combination of
maintenance methodologies is most appropriate
and effective for operating highly reliable and
productive assets and platforms.
38
History of RCM
• ‘Reliability-Centered Maintenance (RCM) was initially developed by the commercial aviation industry to improve the safety and reliability of their equipment.’
• In 1974, the Department of Defense commissioned United Airlines to report on standard maintenance practices and programs for commercial aircraft.
• In 1978, a report written by Stanley Nowlan and Howard Heap and titled Reliability Centered Maintenance was released which documented RCM for the first time.
39
Preventative Maintenance in the
Airline Industry
• Previous to the Nowlan and Heap report in 1978 the traditional maintenance approach in the commercial airline industry was to perform scheduled maintenance at fixed time intervals – Preventative Maintenance (PM).
• PM assumes that failure probabilities can be determined statistically for equipment and components so that corrective action can be taken to prevent catastrophic failure.
Reliability Centered Maintenance, By Nowlan and Heap
40
Preventative Maintenance:
Assumptions
• Correlation between age and/or usage and failure rate.
Increased Age or Usage = Increased Probability of Failure
• For many systems and components this assumption is not valid.
41
Findings from the RCM Report
• What was found through the maintenance study:
– Scheduled overhaul has little effect on the overall reliability of a complex item unless the item has a dominant failure mode.
– There are many items for which there is no effective form of scheduled maintenance.
• Preventative maintenance alone is not the most effective methodology for conducting maintenance.
42
Conclusions from the RCM
Report
• A better understanding of the failure process in complex equipment has actually improved reliability by making it possible to direct preventative tasks at specific evidence of potential failure. – More effective to perform maintenance based on current
and future predicted condition of the equipment.
• Use a systematic approach to evaluate:– Functions and failure modes of a system
– Assess the risk and criticality of the failure modes
– Perform a defined decision process to evaluate the most effective form of maintenance for each system and application.
43
Summary
• There are several maintenance methodologies that
can be used to perform maintenance.
• RCM is a process that helps evaluate the most
effective methodology and combination of
methodologies for achieving a high reliability for the
system being maintained.
– Applied maintenance will be system, equipment and
component specific.
– Dependent upon the application and the operating context
44
A Reduction in Total Life Cycle Costs with
Reliability Centered Maintenance (RCM) and
Condition Based Maintenance (CBM+)
45
Department of Defense:
RCM Policy
• DoD Manual Number 4151.22-M, June 30, 2011
• POLICY. “it is DoD policy that, as one of the key enablers
of Condition Based Maintenance Plus (CBM+) and the
life-cycle sustainment of DoD weapon systems, RCM shall
be used to ensure effective maintenance processes are
implemented.”
– ‘Direct incorporation of RCM throughout the total system
life cycle, from requirements development through
disposal.’
– ‘There is a close relationship between RCM and CBM+. RCM
provides the evidence of need for other CBM+ processes
and technologies, such as health monitoring or prognostics.’
46
Logistics Effort that Support
TLCSM
• Total Life Cycle System
Management (TLCSM) sets
goals, tracks progress and
status, and balances
resources to accomplish
desired material readiness.
Reference: Condition Based Maintenance Plus DoD Guidebook, May 2008
• CBM+, in concert with the other TLCSM tools will enhance
materiel readiness:
– CPI: Continuous Process Improvement
– M&S: Cause-and-effect predictive modeling and simulation
– PBL: Desired outcomes achieved through Performance
Based Logistics
47
Total Ownership Cost
Nominal Life-Cycle Cost of Typical DOD Acquisition Program with a 30-Year Service Life
48
Total Ownership Cost
• Studies show that about
85 percent of the
operating and support
costs of a weapon system
will be determined as
soon as requirements are
set, while less than 10
percent of the life-cycle
cost have been spent.
• By the time a product is
ready for production, over
90 percent of the
operating and support
costs have been
determined, and about 28
percent of the total life-
cycle costs have been
spent.
United States General Accounting Office, Report to the Subcommittee on Readiness and
Management Support, Committee on Armed Services, U.S. Senate, ‘Setting Requirements Differently
Could Reduce Weapon Systems’ Total Ownership Costs’ February 2003
50
Aviation Applied Technology
Directorate (AATD)
The Army S&T goal to decrease O&S cost by reducing maintenance,
which was derived from the Rotary Wing Vehicle Technology Development
Approach and the Aviation S&T Strategic Planning Workshops, supports
this transition to CBM.
• Specific 2013 program metrics:
• 50% Reduction in Inspections/ Flight Hour
• 12% Reduction in Maintenance Labor/ Flight Hour
• 15% Increase in Component Mean Time between Removals
• less than 5% False Removal Rates and 10 hr detection time before
failure measured against a 2005 fielded aircraft baseline.
An integrated set of technologies is required to provide aviation platforms
the ability to accurately assess health and project failure of critical aircraft
components, based on actual usage in operational environments.
53
CBM+ Benefits that Reduce O&S Costs
• Diagnostic
– Reduce Misdiagnosis/NFF: It is difficult to determine rate of occurrence
accurately but rough determination by system or component can be
made with conservative engineering estimates.
• Restocking fee cost avoidance for reducing NFF’s
• Disposal cost avoidance for misdiagnosed parts like batteries.
• Predictive/Prognostic:
– Avoid Catastrophic Failure: Detect and alleviate fault before significant
damage occurs, which may eliminate a total component rebuild.
– Collateral Damage: Detect and alleviate fault before significant damage
occurs may eliminate damage to other components/systems.
• Other Benefits:
– Availability: CBM enables increased availability through predictable
maintenance activity.
– Contract Logistic Services: Potentially reduce the number of support
Field Service Representative (FSR) with the implementation of
embedded health management technology.