FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

STEP 1
Develop/update
RCM Program Plan

STEP
STEP2A
2

STEP
STEP2B
2

STEP 7

STEP 9

Current
Equipment Design

New
Equipment Design
Recommended

Perform
Functional Significance Determination for each function

FUNCTIONAL SIGNIFICANCE DETERMINATION LOGIC

STEP 3

Does the loss of function have an adverse effect

on safety or environment?

Yes

STEP 10

SSWG

Yes

Select
Severity Class for the
failure mode

System Safety input to

Severity Classification
of failure modes

Yes

STEP 11

STEP 13

Yes

Complete
FMECA.

Calculate or estimate
failure distribution
curve

No
Complete
End Item & Level 1
Breakdown

Does the loss of function have an adverse effect

on operations?
No

STEP 4

Does the loss of function have an adverse effect

on economic?

Identify
all failure modes and
their failure effects
(Local, Next Higher &
End Effects)

No
Complete
Level 2 Breakdown

Is this function protected by an existing PM task?

No
NON-SIGNIFICANT FUNCTION

STEP 5

SIGNIFICANT FUNCTION
Select a failure mode for
RCM Analysis and
perform
STEPS 11 thru 23

Complete
Levels 3 and 4
Breakdowns

Steps 8 and up steps are not to be

performed for this function.

STEP 6

Perform STEP 7 for next function.

Identify
all functions

STEP 14

Calculate or estimate time

to first failure

STEP 8
STEP 12
Identify
all functional failures
and Compensating
Provisions

RCM ANALYSIS TASKS

RELIABILITY ANALYSIS

IMPLEMENTATION TASKS

REDESIGN / CIP TASKS

OPERATIONS

OTHER EVENTS

FMECA TASKS

FEEDBACK TASKS

Collect failure and

test data

2-7
2 8 (Blank)

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

STEPS 18

Answer
failure consequences questions.
(MODULE 10)

Is
Is the
the functional
functional failure
failure or
or effect
effect of
of the
the failure
failure mode,
mode, on
on its
its own,
own, evident
evident to
to the
the operator
operator while
while performing
performing normal
normal duties?
duties?

YES

NO

EVIDENT
EVIDENT
Does
Does the
the failure
failure mode
mode cause
cause aa function
function loss
loss or
or secondary
secondary damage
damage that
that
could
could have
have an
an adverse
adverse effect
effect on
on operating
operating safety
safety or
or lead
lead to
to serious
serious
environmental
environmental violation?
violation?

HIDDEN
HIDDEN
Does
Does the
the occurrence
occurrence of
of the
the hidden
hidden failure
failure mode
mode in
in combination
combination with
with aa second
second
failure
failure // event
event cause
cause aa function
function loss
loss or
or secondary
secondary damage
damage that
that could
could have
have an
an
adverse
adverse effect
effect on
on operating
operating or
or lead
lead to
to serious
serious environmental
environmental violation
violation safety?
safety?

NO

YES
Evident
Safety / Environment

STEP 15

NO

Evident
Economic / Operational

YES

YES

Hidden
Economic / Operational

Will this failure mode

happen within the
service life of the
equipment?

Hidden
Safety / Environment

NO

Steps 16 and up steps are not to

be performed for this failure
mode.
GO TO STEP 23

STEP 18A

STEP 18A

STEPS 18A THRU 18F

REQUIRED
INFORMATION (as
applicable, not all data
required for all FMs)

Develop
PHM task
STEP 18B
Develop
Servicing / Lubrication PM task

STEP 16
Develop
PHM task

Determine whether failure

has PF, wear out, or
random type failure
characteristics

STEP 18B
Develop
Servicing / Lubrication PM task

Description for each task

STEP 18C

STEP 17

STEP 18C

Determine
Number of OC or PHM
tasks required during PF
interval to meet Pacc

Develop
On-Condition PM task

Determine or estimate
PF condition, PF-FF
interval or wear out/life
limit age

Develop
On-Condition PM task

STEP 18D

STEP 18D

Determine
PM intervals for all tasks

Develop
Hard Time PM task

Develop
Hard Time PM task

Determine
Single task total manhours and cost

STEP 18E

STEP 18E
Develop
Other Action

Develop
Other Action

STEP 18F

Develop
Failure Finding PM task

2-7
2 8 (Blank)

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

B

STEP 19

STEP 19

STEP 19

STEP 19

Determine costs
associated with each
STEP 18A thru 18E item

Determine costs
associated with each
STEP 18A thru 18E item
+
No action taken costs

Determine costs
associated with each
STEP 18A thru 18F item
+
No action taken costs

Determine costs
associated with each
STEP 18A thru 18F item

STEP 20

STEP 20

STEP 20

STEP 20
Analysis / Select
which option or combination of
options is best at meeting RCM
metrics

PM Task/s
required

Redesigned
required

Analysis/ Select
which option or combination of
options is best at meeting RCM
metrics

Redesigned
required

Analysis/ Select
which option or combination of
options is best at meeting RCM
metrics

No action
required

PM Task/s
required

STEP 23
Repeat
STEPS 11 thru 23 until all
FM(s) have been analyzed

Is hardware in-service or undergoing design testing?

Analysis/ Select
which option or combination of
options is best at meeting RCM
metrics

PM Task/s
required

Design Testing

In-service

STEP 24

STEP 24

Review RCM results with

designers and potential
operators/maintainers for
inputs

Review RCM results with

SSWG, FST, maintainers
and operators for inputs.
(MODULE 14)

Redesigned
required
Recommended PM
acceptable?

STEP 21
GO TO
STEP 2B

YES
GO TO
STEP 2B

Provide
usage prediction data (STEP 13) to logistics to
ensure adequate replacement parts are available

STEP 25

Perform
Packaging Process

No additional analysis is required.

GO TO STEP 23

STEP 22
Was engineering judgment / estimated values
used during any part of the RCM analysis?

*-

YES

PMA / APML

Develop
Age Exploration task

STEP 26
Perform LORA and update
maintenance plan

NO
Direct PM task to be implemented
regardless of RCM results

NO

Go to
STEP 2B

FULL RCM PROGRAM TASK SEQUENCE FLOWCHART

F
STEP 27
Implement
PM tasks

STEP 28
Collect
test and in-service data

STEP 29
Does new data support
current FMECA and RCM
entries?
YES

Go to
STEP 28

NO

Go to
STEP 6