A reliability centered maintenance strategy for a discrete part manufacturing facility

A specialized maintenance decision support system based on Reliability Centered Maintenance (RCM) and the US dept. Of Defenseʹs Failure Mode, Effect and Criticality Analysis (FMECA) has been developed. It was constructed using a modular approach which uniquely integrates the virtues of RCM and FMECA to perform the failure analysis function. A Logic Tree Analysis (LTA) module supports the decision process by performing Cost and Maintainability evaluation to promote the most appropriate maintenance tasks. The Maintenance Planning Module applies “Theory of Constraints” to fit tasks into the production schedule. Apart from a conventional focus on addressing operational failure modes, it takes environmental impact and human safety concerns into perspective in developing tasks directed at achieving higher levels of equipment availability and effectiveness. Ultimately, it contributes to higher quality product manufactured at a significantly lower overall cost. Initial field test results for Miami, Florida based manufacturing system are reviewed.