1 General
This document describes the high-level information for RCM training and the RCM Levels.
2 Basics
This curriculum describes the high-level structure of the RCM Level 1 training.
RCM (Reliability-Centered Maintenance) is a standardized methodology according to SAE JA1011 and JA1012.
JA1011 describes the minimum requirements for a process to be called RCM; JA1012 is the guideline for applying RCM correctly.
In JA1011 and JA1012 the RCM terminology is defined, ensuring that all RCM-certified members prevent miscommunication.
RCM is applied to develop maintenance concepts for highly critical systems. These systems are processes (assets), and RCM is often applied to subprocesses (sub-assets), which may include machines, people, procedures, raw materials, quality demands, and safety/health/environmental regulations.
RCM starts with describing an operating context. Based on this, a process FMEA describes the failure behavior. The FMEA is used to select the most effective maintenance task and interval using the RCM decision logic, called the Decision Diagram (DD).
Once RCM has completed the maintenance concept, it must be embedded into a maintenance plan in order to update the maintenance program in the CMMS.
RCM is a team-based approach, because all reasonably likely failure modes must be listed. For each failure mode the most effective maintenance task with interval is determined. This results in a task list (maintenance concept) with overlapping tasks. The concept must be optimized (“nesting”) so the nested list still covers all failure modes while reducing the total number of tasks. Nesting is no longer part of RCM itself. After the maintenance plan is prepared, MTA (Maintenance Task Analysis) can be applied to optimize the task descriptions for a specific operating context. This final list is imported in the CMMS (Maintenance program).
In RCM trainings, a less detailed but faster approach is also explained, called QM (Quick Maintenance). QM is developed by RCM facilitators specifically for low- to medium-critical systems where less detail is acceptable and a faster result is required.
3 Terminology
To ensure the quality of RCM deliverables worldwide, it is of utmost importance to apply RCM terminology correctly. This is why the terminology and the structure is standardized in JA1011 and JA1012.
The certification process ensures that individuals at all RCM Levels understand the terminology and use it correctly within the RCM methodology.
4 Failure behavior
Costs and risks must be managed correctly to create an effective system. But a system cannot operate on its own: people, procedures, materials, quality demands, etc. are required as well.
In the process many realistic failure modes exist and all must be listed in the FMEA.
The identification path towards failure modes is also part of RCM, including the details and the timeline of each failure mode. All this information together (the FMEA) is called failure behavior.
5 RCM development
A 17-year investigation (completed in 1978) resulted in the RCM approach.
Because of its success, parts of RCM were used in other solutions. Since only parts of RCM were used, quality decreased, people died, safety and environmental accidents occurred.
The Ministry of Defense decided that the methodology RCM required a global standard to ensure RCM would be applied correctly.
This resulted in the creation of JA1011 and JA1012.
6 The 7 RCM steps
Any RCM process shall ensure that all of the following steps are performed in the sequence shown:
a. Determine the operational context and the functions and associated desired standards of performance of the asset.
b. Determine how an asset can fail to fulfill its functions (functional failures).
c. Determine the causes of each functional failure (failure modes).
d. Determine what happens when each failure occurs (failure effects).
e. Classify the consequences of failure (failure consequences).
f. Determine what should be performed to predict or prevent each failure (tasks and task intervals).
g. Determine whether other failure management strategies may be more effective (one-time changes).
7 FMEA
The RCM FMEA (Failure Mode and Effect Analysis) lists the details of the realistic failure behavior of the system in its current operating context. The FMEA lists:
- Functions
- Functional failures
- Failure modes
- Failure effects
8 Failure consequences
Once the FMEA is complete, the RCM DD (Decision Diagram) is used to select the most effective task and interval for each failure mode.
To ensure the correct criteria are applied, the DD starts with evaluating failure consequences. The following consequence types are used:
• Hidden consequences
– Hidden failure modes with/without SHE effects and with economic consequences
• Safety / Health / Environmental consequences
– Evident failure modes with SHE and economic consequences
• Economic consequences
– Evident failure modes with economic consequences
9 Maintenance tasks and intervals
Eight task types are defined in RCM:
- On-condition
- Discard
- Restoration
- Combination of tasks
- Failure finding
- Run-to-failure
- Mandatory redesign
- Desirable redesign
For all planned tasks, the RCM formulas are used to calculate the most effective intervals.
10 Worth Doing
RCM does not use FMECA, because the criticality assessment in RCM is not applied within the FMEA but after all details are available.
This results in a significantly better criticality assessment.
Once the maintenance tasks and intervals are completed, and before the maintenance concept is finalized, WD (Worth Doing) must be applied. It is the criticality assessment of RCM and ensures:
Hidden failures
• The task must:
– reduce the probability of a multiple failure to an acceptable level
– reduce SHE effects to an acceptable level
– have acceptable costs
SHE consequences
• The task must:
– reduce SHE effects to an acceptable level
– have acceptable costs
Economic consequences
• The task must:
– have acceptable costs
11 RCM Levels
11.1 RCM Level 1
Certified as Workgroup Member according to the RCC RCM Level 1 certification matrix.
A Level 1:
• Understands RCM terminology and is able to answer questions from an RCM facilitator to apply RCM and QM correctly.
• Has a high-level understanding of the RCM methodology.
• Understands how QM can be applied. Level 1 practitioners may only apply QM when the result will be evaluated and approved by a certified RCM facilitator.
• Applies RCM and QM only under the strict guidance of a certified RCM facilitator.
• Certification is valid for 5 years. Renewal requires an exam score of ≥80%.
11.2 RCM Level 2
Certified as RCM Facilitator according to the RCC RCM Level 2 certification matrix.
• Phase 1: Passed the theoretical exam with a score of ≥80%
• Phase 2: Passed the practical exam with a score of ≥80%
A RCM facilitator is able to apply and explain:
• Which processes should be analyzed using RCM or QM
• RCM terminology
• The RCM approach
• How all RCM steps must be described and how intervals are calculated
• How nesting works
• How MTA is applied for its current operating context
• The quality requirements of the maintenance concept, maintenance plan, and maintenance program
• Why failure behavior is dynamic and not static, and what is required to ensure FMEAs and maintenance programs remain up to date
Certification is valid for 2 years. Renewal is possible when at least 2 RCM and 2 QM analyses are evaluated as “good” by RCM examiners before the 2-year period ends.
11.3 RCM Level 3
Certified as RCM Teacher according to the RCC RCM Level 3 certification matrix.
• Fully understands JA1011 and JA1012 and is able to teach Level 1 and Level 2 students how to apply RCM correctly
• Trains and coaches Level 1 and Level 2 students with an average score of at least 80%.
• Provides input to RCM examiners
• Certification is valid for 2 years. Renewal requires demonstrating that at least 20 Level 1 and 3 Level 2 students successfully completed their certifications.
11.4 RCM Level 4
• The examiner committee selects new examiners from the group of RCM Teachers
• Responsible for RCM certifications, certification matrices and exams worldwide
• Participates in the G11-M committee to periodically review and update JA1011 and JA1012
This document is approved by RCC (RCM Certification Committee).
Januari 2025.