According to a study by Aberdeen in 2015, we've seen a 59% increase in the cost of downtime over the past three years across all industries. Aside from the capital cost and penalties associated with unplanned downtime, decreased customer trust, lack of productivity, and disruption in the supply chain are commonly seen ripple effects associated with it. Maintenance professionals look to the Maintenance Maturity Model to organize their assets and associated maintenance activities. At the top of that pyramid is Reliability Centered Maintenance.
What is Reliability Centered Maintenance (RCM)?
Reliability Centered Maintenance (RCM) is an operational state of optimal maintenance that reduces cost and improves reliability. This program analyzes which maintenance strategy is appropriate for an asset based on the asset’s potential impact on reliability. Based on an asset’s role in reliable production, the strategy might include one or more of the following: reactive maintenance (run to failure), preventative maintenance, and predictive maintenance. An effective RCM strategy enables you to do the right activities, to the right assets, at the right time and manage production risk by focusing on reliability.
RCM enables organizations to:
- Identify production activities that are important to the business and why
- Identify what assets support those activities and how
- Identify potential asset events that prevent those activities from occurring and the resulting consequence
- Identify what can be done to prevent or mitigate the risk the events represent
- Apply continuous improvement to monitor the effectiveness of risk prevention measures
Did you know that with Reliability-Centered Maintenance programs, reduced downtime leads to a 63% increase in ROI?
Most organizations struggle to dedicate the knowledgeable resources needed to establish a new program. By trying to tackle the entire program as a dedicated project, they enter a state of “paralysis by analysis” or the project struggles with competing priorities. Historically, most facilities only perform work on a small subset of the assets they track, usually 20 to 30 percent. There is little payback in analyzing the remainder. A better strategy is to build the program development into the existing work execution and completion process. As work is completed, the assets and failures are analyzed, classified and maintenance strategy either defined or updated. This leverages the 80-20 rule and focuses the effort on the 20 percent of assets that cause 80 percent of the work.
But, how do you manage RCM? You are in luck if you are using IBM Maximo.
Cohesive Solutions’ RCM extension for IBM Maximo allows organizations to automate maintenance optimization within IBM Maximo. This extension can be configured and designed to specifically meet the needs of your organization and will help you:
- Identify what equipment is important and why
- Identify how it fails and the resulting consequences
- Identify what will be done to prevent or mitigate the risk
- Capture and automatically disposition feedback on the effectiveness of those actions
You can also use Maximo’s built in workflow and escalation tools to “push” the data build activities to the appropriate resources as work is completed. Once the program is established, the same tools can be used to monitor for anomalies and push them to the appropriate resources for further analysis and update, an extension of continuous improvement.
Cohesive Solutions team proudly holds the highest number of certified Maximo consultants, and is comprised of industry experts and ex end users of Maximo. Learn more about our RCM extension for IBM Maximo.