Recognize Phase

In this phase, we Recognize the client’s “pains” as it relates to the Grinder equipment (identified as the primary “bad actor”, its barriers to success and the business processes that need to be improved). The system is selected; scope and strategy for the initiative are set along with high level milestones. An initial baseline is conducted to understand system configurations and boundaries, past and current operation performance and equipment failure history. The current state and target state are determined; essentially we will work with you to determine what program success looks like.

Rationalize Phase

As the Recognize phase clearly identified the “Pain of the Client”, the Rationalize phase uses that information to identify key improvement opportunities that could remove the client’s pain.  These steps include:

• The identifiation of system boundaries to perform the analysis
• The selection of RCM Team resources, the time requirement expectations, removal of outside distractions, and meeting logistics (e.g. space, breaks)
• RCM Team training (RCM terminologies/methods, etc.)

Ratify Phase

The Ratify phase is used to establish the picture of the future and rally the team around the targeted metric improvements.  The site leadership team aligns around four things; the vision for the future, a prioritized list of improvement opportunities, an implementation plan and the financial business case for change.  Once these items become the focal points of the project, it gets easier for partnership agreements to be created between operational and support functions. The RCM Blitz™ team performs a risk analysis to help mitigate any issues that may arise with the new processes. Site leadership agrees to relieve the pilot area of traditional constraints and allow them to follow the new process. Finally, the team launches the project charter that details the reason for the change and how it affects everyone.
The project charter consists of the following:

• Analysis contract
• Project risk management and resource plan
• Execution strategy. From the average RCM analysis we see the following:

• 40%   PdM Tasks
• 15%   PM Tasks - Including Operator Checklist or TPM Tasks
• 20%   Redesign – Includes any change in equipment, process or procedures
• 20%   Consequence Reduction – Includes job plans to eliminate human error
• 5%     Failure Finding Tasks – Inspections of hidden function components
• Communication plan established
• KPI/Benefits tracking established

During the second week, the following phases and its components are initiated:

Resolve Phase

In the Resolve phase, we perform the analysis that satisfies the SAE standard JA1011 for RCM that contains the following elements:

• Prepare for the Analysis
• Select the Equipment to be Analyzed
• Identify functions
• Identify functional failures
• Identify and Evaluate (Categorize) the Effects of Failure
• Identify the Causes of Failure
• Select Maintenance Tasks

By the end of the Resolve phase, a customized EMP and a detailed implementation task list are delivered.

RCM Blitz™ is a fully SAE JA1011 compliant RCM Analysis methodology that is an integral part of designing and implementing a failure mode-driven maintenance strategy.  This facilitated process includes Failures Modes Effects and Criticality Analysis (FMECA), Process Verification Techniques, Consequence Reduction Tasks, Spare Parts Strategy and Implementation Strategy.

Deliverables

• List of PM/PdM tasks addressing operating environment/envelope
• Identification of induced failures modes of the PM/PdM activities
• A complete maintenance strategy for your equipment
• Comprehensive trouble shooting guide for your equipment
• A complete list of necessary spares required to ensure equipment reliability

Benefits

• Refined operating procedures
• High knowledge transfer rate
• Learn when, where and what type of predictive maintenance technologies to detect critical failures at your facilities
• Put into place failure-finding tasks that will reduce the probability of catastrophic Health, Safety, Environmental (HSE) failures
  Learn how to reduce Mean Time To Restore(MTTR) through the use of consequence reduction tasks
• Learn how to identify where to apply the RCM Blitz™ process based on reliability measures
• When implemented, RCM Blitz™ will reduce emergency/demand maintenance work and unit cost of product by lowering  maintenance costs and improving Overall Equipment Effectiveness (OEE)
• When implemented, RCM Blitz™ will reduce maintenance costs by reducing secondary equipment damage
• Your operations and maintenance people will have increased understanding of how your equipment is supposed to work and the tasks required to keep your equipment reliable
• When implemented, the RCM Analysis will include detailed operations checklists to ensure proper set-up and operation of equipment