TM 5-698-2 Reliability-Centered Maintenance (Rcm) For .
TM 5-698-2TECHNICAL MANUALRELIABILITY-CENTEREDMAINTENANCE (RCM) FORCOMMAND, CONTROL,COMMUNICATIONS, COMPUTER,INTELLIGENCE, SURVEILLANCE,AND RECONNAISSANCE (C4ISR)FACILITIESAPPROVED FOR PUBLIC RELEASE: DISTRIBUTION ISUNLIMITEDHEADQUARTERS, DEPARTMENT OF THE ARMY6 OCTOBER 2006
TM 5-698-2REPRODUCTION AUTHORIZATION/RESTRICTIONSThis manual has been prepared by or for the Government and, except to the extent indicated below, is public property and not subject to copyright. Reprintor republication of this manual should include a credit substantially as follows:"Department of the Army, TM 5-698-2, Reliability-Centered Maintenance(RCM) for Command, Control, Communications, Computer, Intelligence, Surveillance, and Reconnaissance (C4ISR) Facilities, 6 October 2006.
TM 5-698-2Technical ManualNo. 5-698-2HEADQUARTERSDEPARTMENT OF THE ARMYWashington, DC, 6 October 2006APPROVED FOR PUBLIC RELEASE: DISTRIBUTION IS UNLIMITEDRELIABILITY-CENTERED MAINTENANCE (RCM) FOR COMMAND,CONTROL, COMMUNICATIONS, COMPUTER, INTELLIGENCE,SURVEILLANCE, AND RECONNAISSANCE (C4ISR) FACILITIESCONTENTSParagraph PageCHAPTER 1. INTRODUCTION TO RELIABILITY-CENTERED MAINTENANCEPurpose.Scope.References.Availability, maintenance, and reliability .The reliability-centered maintenance (RCM) concept .Benefits of RCM .Origins of RCM .Relationship of RCM to other disciplines.CHAPTER 2. ESSENTIAL ELEMENTS OF A SUCCESSFUL RCM PROGRAMRCM implementation plan.Data collection requirements .Data analysis .Commitment to life cycle support of the program .RCM as a part of design.Focus on the four Ws .CHAPTER 3. MAINTENANCE OF SYSTEMSIntroduction.Categories of maintenance .Categorization by when maintenance is performed .Maintenance concepts .Packaging a maintenance program.CHAPTER 4. FUNDAMENTAL CONCEPTS OF A RELIABILITY-CENTEREDMAINTENANCE PROGRAMObjectives of RCM .Applicability of preventive maintenance .Failure .Reliability modeling and analysis .CHAPTER 5. THE RELIABILITY-CENTERED MAINTENANCE PROCESSOverview.C4ISR candidates for RCM analysis.RCM data sources .PM tasks under RCM.The RCM process.Specific considerations for implementing RCM for C4ISR facilities.Evaluation of alternatives.THIS MANUAL SUPERSEDES TM 5-698-2 DATED 3 MAY 35-45-55-65-75-15-15-25-45-55-285-30i
TM 5-698-2CONTENTSParagraph PageCHAPTER 6. CONTRACTING FOR MAINTENANCEIntroduction to maintenance contracting.Approach for C4ISR facilities.Measures of performance.Scope of the contract.Monitoring performance .Incentives .APPENDIX A REFERENCESAPPENDIX B STATISTICAL DISTRIBUTION USED IN RELIABILITY ANDMAINTAINABILITYIntroduction to statistical distribution .The exponential distribution .The weibull distribution.The normal distribution .The lognormal distribution .APPENDIX C AVAILABILITY AND OPERATIONAL READINESSAvailability .Operational readiness.APPENDIX D ACRONYMS GLOSSARYAPPENDIX E FLEXIBLE RCM METHOLOGY B-3B-4B-5B-1B-1B-2B-3B-4C-1C-2C-1C-3E-1E-1LIST OF 45-55-65-75-85-95-105-115-125-135-146-1iiTitleCost benefits of using RCM for developing PM program .Data sources for the RCM analysis.Non-destructive inspection (NDI) techniques, briefly .Examples of failure mechanisms and modes .Examples of failure effect categorization .Examples of tasks under two categories of preventive maintenance .Examples of effects of operational failures.Methods for modeling reliability .Key features of the GO method .Criteria for applying RCM to products .Types of mechanical systems typical for a C4ISR facility .Typical components comprising the C4ISR facility electrical system .Typical components for a SCADA system .General data sources for the RCM analysis .Potential sources of C4ISR maintainability data .Understanding and using different sources of data .NDI techniques .Information needed for RCM.Example of identified tasks.Packaging the tasks from table 5-4 .Typical questions addressed by a reliability assessment.Steps in design trades.Typical costs considered in cost-benefit analysis .Examples of positive 25-25-35-35-45-95-115-265-265-275-305-316-4
TM 5-698-2CONTENTSLIST OF 5-25-35-45-55-65-7TitleThe RCM process starts in the design phase and continues for the life ofthe system.Applicability of age limit depending on failure pattern .Major categories of maintenance by when performed .Typical approach to categorizing maintenance by where it is performed.An example of packaging PM tasks.Example of how PM cards can be used to document required PM tasks.Block diagram of a simple redundant system .Example of a reliability block diagram.Example of a fault tree (from RAC Fault Tree Analysis ApplicationGuide) .Example of a single line diagram (from IEEE Gold BookStandard Network) .Data elements from FMEA that are applicable to RCM analysis .Example of Failure Modes and Effects Analysis worksheet; DA Form 7610RCM decision logic tree (adapted from MSG-3).Evident failure – hazardous effects .Evident failure – operational effects .Evident failure – economic effects.Hidden failure – hazardous effects.Hidden failure – non-hazardous effects .THIS MANUAL SUPERSEDES TM 5-698-2 DATED 3 MAY -145-175-195-215-235-25
TM 5-698-2CHAPTER 1INTRODUCTION TO RELIABILITY-CENTERED MAINTENANCE1-1. PurposeThe purpose of this technical manual is provide facility managers with the information and proceduresnecessary to develop and update a preventive maintenance (PM) program for their facilities that is basedon the reliability characteristics of equipment and components and cost. Such a PM program will help toachieve the highest possible level of facility availability at the minimum cost.1-2. ScopeThe information in this manual reflects the commercial practices and lessons learned over many years ofdeveloping cost-effective preventive maintenance programs for a wide variety of systems and equipment.It specifically focuses on developing PM programs for electrical and mechanical systems used incommand, control, communications, computer, intelligence, surveillance, and reconnaissance (C4ISR)facilities based on the reliability characteristics of those systems and economic considerations, whileensuring that safety is not compromised. The process for developing such a PM program is calledReliability-Centered Maintenance, or RCM. Two appendices develop key topics more deeply: appendixB, statistical distribution; and appendix C, availability.1-3. ReferencesAppendix A contains a complete list of references used in this manual.1-4. Availability, maintenance, and reliabilityIn addition to the following key terms, the glossary lists acronyms, abbreviations, and additionaldefinitions for terms used in this document. Additional terms are included to help the reader betterunderstand the concepts presented herein.a. Availability. (Also see appendix C). Availability is defined as the instantaneous probability that asystem or component will be available to perform its intended mission or function when called upon to doso at any point in time. It can be measured in one of several ways.(1) Operational availability(Ao). Another equation for availability directly uses parameters relatedto the reliability and maintainability characteristics of the item as well as the support system. Equation 1reflects this measure.Ao Mean Time Between Maintenance (MTBM)Mean Downtime MTBMEquation 1(2) Inherent availability(Ai). In equation 1, MTBM includes all maintenance required for anyreason, including repairs of actual design failures, repairs of induced failures, cases where a failure cannotbe confirmed, and preventive maintenance. When only maintenance required to correct design failuresare counted and the effects of the support system are ignored, the result is inherent availability, which isgiven by equation 2.1-1
TM 5-698-2Ai Mean Time Between Failure (MTBF)Mean Time to Repair MTBFEquation 2b. Maintenance. Maintenance is defined as those activities and actions that directly retain the properoperation of an item or restore that operation when it is interrupted by failure or some other anomaly.(Within the context of RCM, proper operation of an item means that the item can perform its intendedfunction.) These activities and actions include removal and replacement of failed items, repair of faileditems, lubrication, servicing (includes replenishment of consumables such as fuel), and calibrations.Other activities and resources are needed to support maintenance. These include spares, procedures,labor, training, transportation, facilities, and test equipment. These activities and resources are usuallyreferred to as logistics. Although some organizations may define maintenance to include logistics, it willbe used in this TM in the more limited sense and will not include logistics.(1) Corrective maintenance. Corrective maintenance is maintenance required to restore a faileditem to a specified condition. Restoration is accomplished by removing the failed item and replacing itwith a new item, or by fixing the item by removing and replacing internal components or by some otherrepair action.(2) Preventive maintenance. Scheduled maintenance or maintenance performed based on thecondition of an item conducted to ensure safety, reduce the likelihood of operational failures, and obtainas much useful life as possible from an item.(3) Condition-based maintenance. Condition-based maintenance can be performed on the basis ofobserved wear or on predicting when the risk of failure is excessive.(a) Some items exhibit wear as they are used. If the probability of failure can be related to ameasurable amount of wear, it may be possible to prescribe how much wear can be tolerated before theprobability of failure reaches some unacceptable level. If so, then this point becomes the criterion forremoval or overhaul. Measurement can be done using a variety of techniques depending on thecharacteristic being measured. The length of cracks in structures, for example, can be measured using xray and ultrasound.(b) In predictive maintenance, a given operating characteristic of the item, vibration ortemperature, for example, is trended and compared with the known "normal" operating levels. Anacceptable range is established with either upper and lower limits, or some maximum or minimum level.As long as the trend data remain inside the acceptable level, any variation is considered to be normalvariation due to variances in materials, operating environment, and so forth. When the trend lineintersects the "unacceptable" limit line, preventive maintenance is required to prevent a failure in thefuture. The limits are based on knowledge of the normal operating characteristics and the level of risk offailure we are willing to accept.c. Reliability. Reliability is defined as the probability that a component can perform its intendedfunction for a specified time interval (t) under stated conditions.d. Reliability-centered maintenance (RCM). RCM is a logical, structured framework for determiningthe optimum mix of applicable and effective maintenance activities needed to sustain the operationalreliability of systems and equipment while ensuring their safe and economical operation and support.Although RCM focuses on identifying preventive maintenance actions, corrective actions are identifiedby default. That is, when no preventive action is effective or applicable for a given item, that item is run1-2
TM 5-698-2to failure (assuming safety is not at issue). From that perspective, RCM identifies all maintenance. RCMis focused on optimizing readiness, availability, and sustainment through effective and economicalmaintenance.1-5. The reliability-centered maintenance conceptPrior to the development of the RCM methodology, it was widely believed that everything had a "right"time for some form of preventive maintenance (PM), usually replacement or overhaul. A widespreadbelief among many maintenance personnel was that by replacing parts of a product or overhauling theproduct (or reparable portions thereof), that the frequency of failures during operation could be reduced.Despite this previous commonly held view, the results seemed to tell a different story. In far too manyinstances, PM seemed to have no beneficial effects. Indeed, in many cases, PM actually made thingsworse by providing more opportunity for maintenance-induced failures.a. Airline study. When the airline companies in the United States observed that PM did not alwaysreduce the probability of failure and that some items did not seem to benefit in any way from PM, theyformed a task force with the Federal Aviation Administration (FAA) to study the subject of preventivemaintenance. The results of the study confirmed that PM was effective only for items having a certainpattern of failures. The study also concluded that PM should be required only when required to assuresafe operation. Otherwise, the decision to do or not do PM should be based on economics.b. RCM approach. The RCM approach provides a logical way of determining if PM makes sense for agiven item and, if so, selecting the appropriate type of PM. The approach is based on the followingprecepts.(1) The objective of maintenance is to preserve an item's function(s). RCM seeks to preserve systemor equipment function, not just operability for operability's sake. Redundancy improves functionalreliability but increases life cycle cost in terms of procurement and life cycle cost.(2) RCM focuses on the end system. RCM is more concerned on maintaining system function thanindividual component function.(3) Reliability is the basis for decisions. The failure characteristics of the item in question must beunderstood to determine the efficacy of preventive maintenance. RCM is not overly concerned withsimple failure rate; it seeks to know the conditional probability of failure at specific ages (the probabilitythat failure will occur in each given operating age bracket).(4) RCM is driven first by safety and then economics. Safety must always be preserved. Whensafety is not an issue, preventive maintenance must be justified on economic grounds.(5) RCM acknowledges design limitations. Maintenance cannot improve the inherent reliability – itis dictated by design. Maintenance, at best, can sustain the design level of reliability over the life of anitem.(6) RCM is a continuing process. The difference between the perceived and actual design life andfailure characteristics is addressed through age (or life) exploration.c. RCM concept. The RCM concept has completely changed the way in which PM is viewed. It isnow a widely
TM 5-698-2 1-2 Mean Time to Repair MTBF Mean Time Between Failure (MTBF) A i Equation 2 b. Maintenance.Maintenance is defined as those activities and actions that directly retain the proper
Test-Retest Reliability Alternate Form Reliability Criterion-Referenced Reliability Inter-rater reliability 4. Reliability of Composite Scores Reliability of Sum of Scores Reliability of Difference Scores Reliability
Reliability Infrastructure: Supply Chain Mgmt. and Assessment Design for reliability: Virtual Qualification Software Design Tools Test & Qualification for reliability: Accelerated Stress Tests Quality Assurance System level Reliability Forecasting: FMEA/FMECA Reliability aggregation Manufacturing for reliability: Process design Process variability
2015 Nissan Frontier - - - - 2015 Nissan Frontier - - - - TOTAL 80,500 698,300 75,000 625,000 950,200 2,429,000 PROJECT FUNDING SCHEDULE FY21 FY22 FY23 FY24 FY25 5 Year TOTAL FUNDING SOURCES CIP Fund 698,300 625,000 950,200 2,429,000 TOTAL 80,500 698,300 75,000 625,000 950,200 2,429,000 11
posing system reliability into component reliability in a deterministic manner (i.e., series or parallel systems). Consequentially, any popular reliability analysis tools such as Fault Tree and Reliability Block Diagram are inadequate. In order to overcome the challenge, this dissertation focuses on modeling system reliability structure using
Evidence Brief: Implementation of HRO Principles Evidence Synthesis Program. 1. EXECUTIVE SUMMARY . High Reliability Organizations (HROs) are organizations that achieve safety, quality, and efficiency goals by employing 5 central principles: (1) sensitivity to operations (ie, heightenedFile Size: 401KBPage Count: 38Explore furtherVHA's HRO journey officially begins - VHA National Center .www.patientsafety.va.govHigh-Reliability Organizations in Healthcare: Frameworkwww.healthcatalyst.comSupporting the VA’s high reliability organization .gcn.com5 Principles of a High Reliability Organization (HRO)blog.kainexus.com5 Traits of High Reliability Organizations: How to .www.beckershospitalreview.comRecommended to you b
Electronic Parts Reliability Data (2000 pages) Nonelectronic Parts Reliability Data (1000 pages) Nonoperating Reliability Databook (300 pages) Recipe books: Recipe book: MIL-HDBK-217F Military Handbook 338B: Electronic Reliability Design Handbook Automotive Electronics Reliability SP-696 Reliability references:
Electronic Parts Reliability Data (2000 pages) Nonelectronic Parts Reliability Data (1000 pages) Nonoperating Reliability Databook (300 pages) Recipe books: Recipe book: MIL-HDBK-217F Military Handbook 338B: Electr onic Reliability Design Handbook Automotive Electronics Reliability SP-696 Reliability references:
Keywords: Reliability Block Diagrams (RBD); hierarchical reliability model; reliability curve; reliabil-ity evaluation; software libraries 1. Introduction Reliability is defined as "the ability of a system or component to perform its required functions under stated conditions for a specified period of time" [1]. Reliability is often
