RELIABILITY

CENTERED
MAINTENANCE
with Ahmed Said Kotib

2019
2 - 4 OCTOBER
JAKARTA INDONEISA

REGISTER 2
GET 1 FREE
In-house
Public
Excel Momentum Group

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 Course Overview
 Facts and researches proved that Preventive Maintenance (PM) only is not the solution!
Up to 50 percent of unplanned downtime occurs in systems that were "serviced, i.e.
undergone PM" within the previous 7 days, according to research from the Palo Alto,
CA-based Electric Power Research Institute and the U.S. Navy (which means that PM is
not the solution). So, if the goal of the preventive maintenance program is truly to prevent
system interruptions, it's time for maintenance engineers to reconsider their approach to
maintenance!
 RCM provides a solution that integrates the maintenance strategies!
Reliability Centered Maintenance (RCM) is a time-honored, proven process that has
been employed all over the world for over four decades in nearly every industry. Because
its principles are so robust, so powerful, and so versatile, the process has stood the test of
time and human meddling.
 RCM analysis provides a structured framework for analyzing the functions and potential
failures for a physical asset with a focus on preserving system functions, rather than pre-
serving asset. RCM is used to develop scheduled maintenance plans that will provide an
acceptable level of operability, with an acceptable level of risk, in an efficient and cost-ef-
fective manner.
 Reliability-centered maintenance is much more than just another way to do maintenance.
It's a way of looking at system performance in terms of the impact of a failure and then
mitigating those results by design, detection, or effective maintenance.
 RCM is A systematic approach for identifying effective and efficient preventive and con-
dition maintenance tasks for assets and items in accordance with a specific set of proce-
dures and for establishing the intervals between maintenance tasks
 This course is focused on providing a thorough understanding of RCM and the crucial role
it is now playing in determining the optimum maintenance program. Various approaches
to performing RCM analysis are presented and a step by step implementation will be
explained.
 The course is providing full RCM implementation examples and a full RCM Implementa-
tion project guide
 Course Objectives
Upon successful completion of this course, the delegates will be able
to:
 Understand the main types of maintenance and how RCM evolved from them
 Explore the components that comprise an effective maintenance program
 Understand the place of RCM in the business of maintenance and its role in determining
the optimum maintenance program
 Review the history and principles of RCM along with the various approaches
 Present a methodology for applying RCM using examples and working sessions
 Understand what is needed to implement RCM and its results
 Understand the role of condition monitoring and CMMS systems in implementation of
RCM
 Understand and utilize KPIs to measure effectiveness of maintenance performance

Who should attend ?

This course is intended for personnel involved with maintenance of
assets including:

 Reliability (Engineers, Section Leaders, Team Leaders, and Managers)

 Maintenance (Engineers, Planners, Supervisors, Section Leaders, Team Leaders, and
Managers)
 Personnel who are preparing to implement RCM and those who are considering its use.
 Operations and design staff who interact with maintenance.

Participants will receive a thorough overview of all the basic compo-

nents of RCM
 COURSE OUTLINE
For 3 days
The Evolution of RCM Principles
Introduction of Concepts
Maintenance Definition
Reactive Maintenance - Run to Failure Maintenance
Preventive Maintenance
PM Definition
Why PM Plan
PM Scope
Is Preventive Maintenance Effective for preventing all Failures?
What are Infant Mortality and bathtub curve?
Understanding Failure Patterns
When does PM Make Sense?
Preventive Maintenance Program Risks
Successful PM Program
PM Pros and Cons
Predictive Maintenance
Definition
The P-F curve
Case Study: Why Asset Condition Maintenance?
Predictive Technologies
Vibration Analysis
Ultrasonic Detection
Infrared Thermography: What is it?
Oil Analysis
Predictive Maintenance (PdM): Advantages and Disadvantages
Proactive Maintenance
Asset Criticality Assessment/Analysis
Importance and benefits of Asset Criticality Assessment
Criticality Assessment Methodology
Case Study:
ACR Methodology…Quantitative
ACR Methodology…Qualitative
 COURSE OUTLINE
For 3 days
Reliability Centered Maintenance (RCM)
What is Reliability Centered Maintenance (RCM)?
The Essence of RCM: Managing the Consequences of Failure
RCM History
Difference Between RCM and RCA
RCM Published Guidelines and Standards
RCM Objectives
RCM Principles
RCM Integrates Maintenance Strategies
RCM Benefits
Operating Context:
What Is an Operating Context?
When Should an Operating Context Be Drafted?
What is Included in an Operating Context?
The Operating Context as a Living Document
RCM Process
RCM Process Overview
Types of RCM
Rigorous RCM Approach (Also known as Classical RCM)
Rigorous RCM Applications
Intuitive RCM Approach (Also known as Streamlined or Abbreviated
RCM)
Intuitive RCM Approach Applications
RCM Analysis
Building the Strategy Team
Assess Current Maintenance Processes
Develop a Plan
RCM Analysis sequence
RCM Procedure
RCM and Failure Analysis
Step 1: System Selection and Information Collection
Step 2: System Boundary Definition
 COURSE OUTLINE
For 3 days
Identify Subsystems and Components
Step 3: System Description and Functional Block Diagram
System Description Example
System Description Example of IN/OUT Interfaces
Examples of functional block diagram
System Work Breakdown Structure (SWBS)
Asset History: Failure Data Analysis
Step 4: System Functions and Functional Failures
Why Write Functions?
Two Types of Functions
Classifying Functions as Evident or Hidden
Composing Evident and Hidden Functions
What Is a Functional Failure?
Two Types of Functional Failures
Composing Functional Failures
Examples of Functions and Function Failures
Step 5: Failure Mode and Effect Analysis (FMEA) – as part of RCM
What is Failure?
What is Failure Mode?
What Failure Modes Should Be Included in an RCM Analysis?
How Detailed Should Failure Modes Be Written?
What is Failure Cause?
What Is a Failure Effect?
Composing Failure Effects
Writing Failure Effects for Protective Devices
What is Failure Mode and Effects Analysis (FMEA)?
What are the Types and Usage of FMEAs?
Example of FMEA
Step 6: Logic Tree Analysis (LTA): Failure mode criticality (based on
consequences)
What Is a Failure Consequence?
Identifying Failure Consequences
Example of implementing LTA
 COURSE OUTLINE
For 3 days
Step 7: Selection of Maintenance Tasks
Types of Maintenance Tasks
Selection process and decision
Step 8: Task Packaging and Implementation
Step 9: Making the Program a Living One — Continuous Improvements

The Evolution of RCM Principles

Difference Between FMEA & FMECA
FMEA Inputs and Outputs
FMEA Process
Examples of Failure Modes and Causes
Example of FMEA Worksheet
FMEA Worksheet details
Finding the Root Cause through FMEA
Examples of FMEA
NASA FMEA Worksheet
Example from NASA Reference: FMEA Applied on HVAC System
Summary of RCM
RCM: Advantages and Disadvantages
Rate Your RCM Against the Scoreboard for Maintenance Excellence
CMMS as a tool for implementing RCM and maintenance strategies
What is a CMMS?
CMMS Capabilities
CMMS is a Planning Tool
CMMS Keys!
Asset Health - Job Plans
Writing a Job Plan
Work Pack Minimum Content
Creating Procedures and Check Sheets with the Quality that Improves
Reliability
Why Put Quality Control in Procedures?
 COURSE OUTLINE
For 3 days
Key Performance Indicators (KPIs) as a Tool for
Performance Improvement and Work Control
Types of Planning and Maintenance Key Performance Indicators (KPI)
Leading & Lagging KPIs, what is the Difference?
Examples of Key Performance Indicators (KPIs)
Reliability definition and calculation
Reliability Indicator (MTBF)
Maintainability Indicators (MTTR) and Failure Rate
Availability definition and calculation
Utilization
What is OEE?
What is TEEP?
Benchmarking against the Industry Best Practices
What is Benchmark?
Benchmarking - Objectives
Examples of Maintenance and Reliability Best Practice Benchmarks along
with their Related Typical World Class Values
Project Guide for RCM Implementation
Section-1: Introduction
Section-2: An RCM Primer
Section-3: Deciding to Conduct an RCM Project
Section-4: Valuable Lessons Learned by Other Organizations
Section-5: Completing an RCM Study
Section-6: Implementing the RCM Study
Section-7: Measuring the Benefits
Section-8: Sustaining an RCM Program
Wrapping up

Training Methodology
The program will be highly interactive, with opportunities to advance
opinions and ideas. Participation is encouraged in a supportive environment.
To ensure the concepts introduced during the program are understood, they
will be reinforced through a mix of learning methods, including lecture style
presentation, open discussion, case studies, exercises, videos, and group work.
 Ahmed Said Kotib
More than 30 years of experience in Maintenance, Maintenance Planning, Shutdown / Turna-
round Planning and Reliability. More than 26 years of experience in Oil and Gas Industry in
international leading companies: Shell, BP and Total. Planned / participated in planning and
execution of more than 40 major Shutdowns / Turnarounds.
Led/participated in several implementations of different CMMS/AMS systems including
COMAC, IMMPOWER, and Maximo Systems. Due to his experience in CMMS/AMS Imple-
mentations, he was appointed as a project leader for one of the largest Asset Management
System Implementation Projects in the GCC region which covered about 180,000 Assets and
Tags. Participated in all stages of EPC Projects for preparation of the asset requirements and
assurance of operation readiness.
International speaker who conducted presentations and workshops in major Oil and Gas and
Petrochemical conferences in US, UK, Germany, Norway, Netherlands, Malaysia, Singapore,
Indonesia, Oman and UAE.

MAINTENANCE PLANNING PROJECTS

Headed the Planning Section in Shell, BP and Total joint venture companies
Participated in founding the maintenance planning section in Shell’s largest Gas Filed in Egyptian
western desert (Bed-3).
Played the main role in establishing the CMMS system for Shell fields in Egyptian Western and East-
ern Deserts (in BAPETCO) from scratch.
Planned / participated in planning and execution of more than 40 major Shutdowns / Turnarounds in
Shell, BP and Total joint venture companies.
Developed important business processes such as Shutdown Business Process (in 2011) and
Integrated Activity Planning Process (in 2012) for BP/Total (ADMA-OPCO).
Was the Project Leader for the implementation of the Asset Management System (Maximo 7.5 Oil
and Gas) in BP (ADMA-OPCO’s) new fields (Mega Projects) where the scope of work covered full
implementation requirements for about 180,000 tag numbers
Developed for ADMA OPCO’s new fields mega projects: Asset Management System project imple-
mentation strategy, scope of implementation work, and a guideline for proper utilization of Spare
Parts Interchangeability Records (SPIR) by Manufacturers and Vendors dealing with Company’s EPC
Contractors
 RELIABILITY CENTERED
MAINTENANCE emg
2nd to 4th of October 2019 in Jakarta, Indonesia excel momentum group

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