DEFSTAN 00-45(PT3)/1(2006) : 2006

Foreword
Introduction
SECTION 1 - BACKGROUND TO RELIABILITY CENTRED MAINTENANCE
1 Scope
2 Warning
3 Benefits of RCM
4 Interaction with Integrated Logistic Support (ILS)
5 Process Overview
    5.1 General
    5.2 The Seven Questions of RCM
6 Overall Requirement
    6.1 Cost Effectiveness
    6.2 Tailoring the Requirement
SECTION 2 - APPLYING RCM TO AN END ITEM
7 Introduction
8 Preparatory Work
    8.2 RCM Project Plan (RCMPP)
    8.3 Scope of the RCM Analysis
    8.4 End Item Operating Context
    8.5 Identification of Contributing Authorities
    8.6 Construction of the Functional Model
    8.7 Allocation of Analysis Identification/Control Numbers
    8.8 Determination of the Functional and Physical Analysis
          Boundaries
    8.9 Production of an End Item Compartment or Zonal Plan
    8.10 Identification of Structurally Significant Items
    8.11 Interrogation of Existing RCM Databases for Suitable
          Templates
    8.12 Collection of Supporting Documentation and Data
    8.13 Formation of an Analysis Team
    8.14 Assumptions, Constraints and Ground Rules for the
          Programme
9 RCM Analysis
10 Maintenance Task Rationalization and Packaging
11 Production of Maintenance Schedules
12 Maintenance Programme Implementation
13 Sustaining the Programme
SECTION 3 - RCM WITHIN ILS
14 Introduction
15 RCM Activity
16 Task 101 - LSA Strategy
17 Mandated Activities
18 Timing
19 Commercial Off-The-Shelf (COTS)
20 Task 102 - LSA Plan
21 Task 103 - Programme and Design Reviews
22 Task 201 - Use Study
23 Task 303 - Evaluation of Alternatives and Trade-off
    Analysis
24 Task 401 - Task Analysis
25 Def Stan 00-45 Considerations
SECTION 4 - END ITEM OPERATING CONTEXTS
26 Purpose
27 Description
    27.4 Capability Requirements and Construction
    27.5 Engineering Disciplines
    27.6 End Item Operating Context Data Sources
SECTION 5 - FUNCTIONAL MODELLING AND RCM CANDIDATE SELECTION
28 Introduction
29 Functional Model Requirements
30 Required Detail
    30.1 Level of Resolution
    30.2 Allocating Assets to Functions
31 Functional Model Verification
32 Allocation of Analysis Identification or Control Numbers
33 Significant Candidates for RCM Analysis
34 Output
SECTION 6 - ANALYSIS LEVEL OPERATING CONTEXTS
35 Introduction
36 Description
37 Analysis Boundaries
38 Sources of Information
39 Standard Numbering Systems
SECTION 7 - FAILURE MODES, EFFECTS AND CRITICALITY ANALYSIS
40 The FMECA Process
41 Functions
    41.1 Containment
    41.2 Environmental Integrity
    41.3 Alarms and Warnings
    41.4 Indication
    41.5 Protection
    41.6 Safety
    41.7 Appearance
    41.8 Comfort
    41.9 Control Mechanisms
    41.10 Structural Integrity
    41.11 Security of Attachment
    41.12 Efficiency/Economy
42 Functional Failures
43 Compensating Provisions
44 Failure Detection
45 Failure Modes
46 Failure Mode Indicator
47 Failure Effects
    47.1 Impact on Operation, Safety and the Environment
    47.2 Evaluation of Corrective Action
48 Failure Probability Level
49 Hazard Severity Classification
50 Criticality Analysis
51 Output
SECTION 8 - RCM DECISION LOGIC
52 Introduction
53 Consequence Analysis
54 Preventive Maintenance Task Criteria
55 Quantitative Descriptions of Failure
    55.1 Reliability Indices
    55.2 Failure Rate
    55.3 Mean Time Between Failures
    55.3 Reliability Function
    55.4 Conditional Probability of Failure
56 Age Reliability Characteristics
57 Task Effectiveness
58 On-Condition Tasks
    58.1 Description
    58.2 On-condition Task Applicability
    58.3 On-condition Task Intervals
    58.4 Event Initiated On-condition Tasks
59 Hard Time Tasks
    59.1 Description
    59.2 HT Task Applicability
    59.3 HT Task Intervals
    59.4 Event Initiated Hard Time Tasks
60 Failure Finding Tasks
    60.1 Description
    60.2 FF Task Applicability and Effectiveness
    60.3 FF Task Intervals and Hidden Function Availability
61 Using the FFI Formulae
    61.1 General
    61.2 Choosing the Appropriate Formula
    61.3 Formula Validity
    61.4 Task Feasibility
    61.5 The MTBF[PF]/FFI Ratio
    61.6 Terms Used in FF Formulae
62 Support Tasks
    62.1 General
    62.2 Recording Asset Usage
    62.3 Collection of Performance Data
    62.4 Retrieval of Samples
63 Maintenance Cost
64 Task Trade-Offs
65 Health and Usage Monitoring Systems
66 Default Actions
    66.1 Requirement
    66.2 Objectives of Redesign or Change Action
    66.3 Default Actions for Failure Modes with Evident
          Failure Consequences
    66.4 Default Actions for Failure Modes with Hidden
          Failure Consequences
67 Age Exploration Candidates
68 Consolidation of Tasks
69 Task Descriptions
70 Outputs
SECTION 9 - STRUCTURES
71 Introduction
72 Classification of Structure
73 Structural Failure Modes
    73.1 Threats
    73.2 Overload
    73.3 Maintenance or Supply Error
    73.4 Fatigue Damage
    73.5 Accidental Damage (AD)
    73.6 Environmental Deterioration (ED)
74 Safe Life and Damage Tolerant Structure
    74.1 Design Philosophy
    74.2 Damage Tolerant Structure
    74.3 Safe Life Structure
75 Structural Maintenance Tasks
SECTION 10 - ZONAL AND EXTERNAL SURFACE AREAS ANALYSIS
76 Introduction
77 Principles of Zonal and External Surface Area Analysis
78 Zonal and ESA Analysis
    78.1 Zonal Plans
    78.2 Required Details
    78.3 ED Assessment
    78.4 AD Assessment
    78.5 Zonal and ESA Rating
    78.6 Zonal and ESA Survey Intervals
    78.7 Policy Directed Inspections
    78.8 Attendant Personnel
    78.9 Equipment Removals
    78.10 Access Requirements
    78.11 Electrical Cables and Connectors
    78.12 Pre and Post Use Inspections
    78.13 Survey Analysis Process
79 Cleaning of Zones
SECTION 11 - RATIONALIZATION OF PM TASKS AND THE DEVELOPMENT
             OF THE MAINTENANCE PROGRAMME
80 Introduction
81 Use of Conversion Factors
82 Levels of Maintenance
83 Task Elapsed Time
84 Initial Packaging Assessment
85 Packaging the Deep Maintenance Level Tasks
86 Packaging the Intermediate Maintenance Level Tasks
87 Packaging the First Line Maintenance Tasks
88 Out of Phase Maintenance
89 Rationalization as a Result of Equipment Removal
90 Use of Maintenance Backstops
91 Special Considerations for HUMS Driven Tasks
92 Recording Rationalised Task Intervals
93 Output
SECTION 12 - MAINTENANCE PROGRAMME SUSTAINMENT
94 Introduction
95 Collecting Performance and Usage Data
96 Interpretation of Performance and Usage Data
    96.1 Objectives
    96.2 Top Degrader Ranking
    96.3 Trend Analysis
    96.4 Task Packaging Reviews
    96.5 Fleet Leader Programmes
    96.6 Age Exploration Tasks
    96.7 Emergent Issues
97 Engineering and Operational Influences
98 Feedback from In-Service Engineering Logistics
99 IPT Inputs
100 PM Programme Continuous Reviews
SECTION 13 - AGE EXPLORATION
101 Introduction
102 Objectives, Principles and Guidelines
103 Analysis Techniques
104 Degradation Analysis
105 Actuarial Analysis
106 Applying Sampling Techniques
107 Random Sampling
108 Opportunity Sampling
109 Threshold Sampling
    109.1 Purpose
    109.2 Single Threshold
    109.3 Opportunity Threshold
    109.4 Dual Threshold
110 Fleet Leader Sampling
111 Constant Density Sampling
112 Structures Sampling
113 AE Priorities
114 AE Tasks for Safety Related Failure Consequences
    114.1 Methods
    114.2 Controlled AE Tasks
    114.3 Operational AE Tasks
115 AE Tasks for Non-Safety Related Failure Consequences
116 AE Data Collection
117 Applying the Results of an AE Analysis
    117.1 Requirement
    117.2 Adjusting Maintenance Intervals
    117.3 Adjusting Maintenance Tasks
    117.4 Modifying AE Sampling Programmes
118 Recommendations for AE
119 Output
SECTION 14 - AUDITING
120 Purpose
121 Types of Audit
    121.1 Process Audit
    121.2 Technical Audit
    121.3 Authorship Audit
122 Auditors
    122.1 Process Auditors
    122.2 Technical Auditors
    122.3 Authorship Auditors
123 Procedures and Documentation
SECTION 15 - ADDITIONAL GUIDANCE ON THE APPLICATION OF RCM
124 Introduction
Annex A - Maintenance Costing
Annex B - RCM Structures Analysis for Naval Vessels
    B.1 Introduction
    B.2 Background
    B.3 Load Bearing Structure
    B.4 Containment and other Functions
    B.5 Structural Failure Categories
          B.5.1 Fatigue Damage (FD)
          B.5.2 Environmental Deterioration (ED)
          B.5.3 Accidental Damage (AD)
    B.6 Ship Structure and Structurally Significant Items
          B.6.1 Significant Structure
          B.6.2 Other Structure
          B.6.3 Identification of Structurally Significant
                  Items
          B.6.4 SSI Consolidation
    B.7 Structural Survey and Monitoring
    B.8 The Structural Analysis Process
          B.8.1 General
          B.8.2 Identification of Analysis Boundary
          B.8.3 Operating Context
          B.8.4 Structural FMECA
    B.9 Completing the Analysis
    B.10 Fatigue Damage Analysis
          B.10.1 Analysis Criteria
          B.10.2 Safe Life Analysis
          B.10.3 Damage Tolerant Analysis
          B.10.4 An Alternative Approach for the Analysis
                  of Fatigue Damage
          B.10.5 Environmental Deterioration Analysis
          B.10.6 Threat Reduction Effect of Cathodic
                  Protection
          B.10.7 Accidental damage Analysis
          B.10.8 Damage Tolerant Structures
          B.10.9 Safe Life Structure
          B.10.10 Accidental Damage Risk Assessment
          B.10.11 The AD Task Interval
          B.10.12 Accidental Damage Task Interval for Damage
                  Tolerant Structure
          B.10.13 Accidental Damage Task Interval for Safe
                  Life Structure
    B.11 Deriving the Natural Interval for Inspection
          B.11.1 General
          B.11.2 Fatigue Damage
          B.11.3 Environmental Deterioration and Accidental
                  Damage
          B.11.4 Example Scenario
          B.11.5 Task Consolidation and Packaging
    B.12 Influence of Build and Design Quality (B&DQ)
    B.13 Age Exploration Considerations
          B.13.2 The main considerations for AE are as follows:
    B.14 Analysis of Non-Metallic Structure
          B.14.1 Nature of Materials
          B.14.2 Fatigue Damage
          B.14.3 Environmental Damage
          B.14.4 Accidental Damage
                  B.14.4.1 GRP Defect Types
Annex C - RCM Structures Analysis For Aircraft
Annex D - Example Checklists for RCM Audits
    D.1 RCM Process Audit
    D.2 RCM Technical Audit
    D.3 RCM Authoring Audit
Annex E - Lightning/High Intensity Radiated Field (L/HIRF)
          Analysis
    E.1 Background
    E.2 L/HIRF Protection Devices
    E.3 Maintenance of L/HIRF Protection Devices
          E.3.1 End Item Structure
          E.3.2 Electrical Wiring Installations
          E.3.3 LRI Protection
Annex F - Earth Bonding Of Electrical Equipment For
          Personnel Protection In The RN
    F.1 Introduction
    F.2 Caveat
    F.3 Background
    F.4 Rationale
          F.4.1 General
          F.4.2 Environmental Baseline
          F.4.3 Exposure to Vibration
          F.4.4 Exposure to AD
          F.4.5 Degree of Exposure
          F.4.6 Lethality
          F.4.7 Shock Effect
          F.4.8 Calculating the Inspection Interval
    F.5 Examples
          F.5.1 General
          F.5.3 Example 1
          F.5.5 Example 2
          F.5.6 Example 3
          F.5.7 Example 4
          F.5.8 Example 5
          F.5.9 Example 6
    F.6 Task Description
    F.7 Populating The RCM Toolkit
    F.8 Host Equipment Earth Faults
    F.9 Endorsement
Annex G - Risk Based Maintenance
    G.1 Introduction
    G.2 Application
    G.3 Limitations