Adding value with

RCM or RCA..

What 's it gonna be?

Ron Vonk / CoThink

July 5th 2016

Introduction

2008 2000 1995 1990

Loopbaan

Ir. Ron Vonk

Partner, senior facilitator & trainer bij CoThink

Why this presentation?

RCM?

RCA?

RCM &

RCA?

Choices made between RCM and RCA prove

not always to be the best ones…

No satisfactory answer when the question is asked:

“Why focus on RCM?” or “Why focus on RCA?”

Content

1. Introduction RCM and RCA

2. Similarities and distinctions

3. Pros and cons

4. Choice between RCM and RCA

5. Conclusions & recommendations

Reliability Centred Maintenance (RCM)

Best practice to determine and optimize a maintenance

program for equipments, to maximize availability for

minimum costs, taking into account all requirements set

in advance

Reliability Centred Maintenance (Wikipedia)

Failure Mode Effect & Criticality Analysis (FMECA)

RCM2 Failure Mode & Effect Analyse (FMEA)

Asset Performance Management Concept (APMC)

Dynamic RCM …. Streamlined RCM

Variants of RCM

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Root Cause Analysis (RCA)

A class of problem solving methods aimed at identifying

the root causes of problems or events, in which a root

cause is used to describe the depth in the causal chain

where an intervention could reasonably be implemented

to change performance and prevent an undesirable

outcome.

Root Cause Analysis (Wikipedia)

RCA approaches

(approaches for continuous

improvement

RCA methods

RATIO

DMAIC

8D

A3

Kaizen SCOPE

….

Event Mapping

Ishikawa Diagram

5 Why

Problem Analysis

Current Reality Tree

Tripod

Barrier analysis

… Apollo

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Content

1. Introduction RCM and RCA

2. Similarities and distinctions

3. Pros and cons

4. Choice between RCM and RCA

5. Conclusions & recommendations

RCM process

RCA process

Similarities RCM and RCA

Method (how) Input Output

Asset/Maintenance objectives

Asset/Maint. performances

Knowledge & experience

Documentation

Improvement proposals

- Preventive Maintenance

- Modifications

- Operation procedures

- ...

Use of methods (FMEA/FMECA/RCM2/…)

Team with facilitator

Use of software (Excel, Optimizer+, …)

Method (how) Input Output

Asset/Maintenance objectives

Asset/Maint. performances

Knowledge & experience

Documentation

Improvement proposals

- Preventive Maintenance

- Modifications

- Operation procedures

- ...

Use of methods (5Why, Event Mapping,..)

Team with facilitator

Use of software (Excel, Optimizer+, …)

Use of methods (FMEA/FMECA/RCM2/…)

Team with facilitator

Use of software (Excel, Optimizer+, …)

Use of methods (5Why, Event Mapping,..)

Team with facilitator

Use of software (Excel, Optimizer+, ...)

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Time Now

Methods to find root

causes, to solve and

prevent a problem that

actually occurred

Methods to prevent

unacceptable potential

problems

RCA RCM

Distinctions between RCM and RCA

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

RCM

RCA

Proactive Reactive

Mostly long during

interventions

Mostly short

interventions

Implementation of

improvement proposals

often difficult

- A lot of work

- Lack of buy-in/support

- Higher probility of budget

issues

Implementation of

improvement proporals

relatively easy

- Less work

- Strong buy-in/support

- Lower probability of

budget issues

Analyses quit often

“boring” (caused by

repetiveness)

Analyses mostly

“exciting” (different

every time)

Distinctions between RCM and RCA

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Content

1. Introduction RCM and RCA

2. Similarities and distinctions

3. Pros and cons

4. Choice between RCM and RCA

5. Conclusions & recommendations

RCM

RCA

Pros and cons RCM and RCA

Pros

Proactive, also potential problems

will be taken in consideration

during analysis

Development or improvement of

maintenance concept for total

equipment

Contribution to compliancy: being

able to demonstrate correct

preventive actions are in place

Pros

Costing less time and money

Rapid results

Less/no challenges to get or

maintain buy-in

Cons

Relatively costly in terms of

money and time

Results less visible on short

term

Obtain and maintain buy-in is

a challenge

Cons

Reactive: problem has already

occurred

Improvement of maintenance

concept (if applicable) only for

part of equipment: to prevent

reoccurance of specific failure

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Content

1. Introduction RCM and RCA

2. Similarities and distinctions

3. Pros and cons

4. Choice between RCM and RCA

5. Conclusions & recommendations

Why RCM or RCA? Bron: Mainnovation,

“VDM, New faith in maintenance”

RCM

RCA RCA

Application of RCM and RCA are recurring

steps in continuous improvement circle!

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Focus RCM better then RCA?

% costs

preventive

maintenance

Benchmark costs of preventive maintenance

As % of total maintenance costs

Organisations in benchmark

Biased preference

for prevention is

sometimes

obstinately!

Is that the reason

why there seems to

be a preference to

focus on RCM

instead of RCA?

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

If we need to decide between Preventive or Corrective

Maintenance, we seem to be wise: we choose based on

risk and minimum total costs

Probability

Seriousness

of

effect

Acceptable

Corrective

measures

Not acceptable

Preventive

measures

Risk = Probability x Seriousness

Costs

preventive

maintenance

Total costs

Why should we do it differently when choosing

between RCM and RCA?

€

Level of preventive maintenance

Costs corrective

maintenance +

downtime costs

Minimum total costs

Focus RCM better then RCA?

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Focus on RCM or RCA?

Big failure, incident

or accident

RCA

Asset/Maintenance objectives

Asset/Maint. Performance

Knowledge & Experience

Documentation

Quick FMECA

Equipment (still)

critical?

No Yes

RCA** RCM

** RCA based on “cost drivers” and “performance killers”

Current

maintenance

concept *

* If there is not (yet) a compliancy issue. Otherwise, start from scretch.

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

Content

1. Introduction RCM and RCA

2. Similarities and distinctions

3. Pros and cons

4. Choice between RCM and RCA

5. Conclusions & recommendations

Conclusions & recommendations

Adding value with RCM or RCA?

It is not “RCM or RCA?”, it should be “RCM and RCA!”

In any case of big failures or incidents: always apply RCA.

Define clear “triggers” though: What is big?

Is compliancy an issue? Apply RCM for critical equipment,

starting with “If we won’t do any maintenance…”

Is compliancy not an issue? Apply RCM for equipment

which are still critical, regardless the current maintenance

concept (where there are still unacceptable risks)

For non-critical equipments: focus with RCA on elimination

of “cost drivers” and “performance killers”!

Introduction RCM

en RCA

Similarities and

disctinctions

Pros and cons

Choice between

RCM and RCA

Conclusions &

recommendations

More info…

CoThink: www.cothink.nl