CMRP Reliability-Centered Maintenance Analysis 2 — Questions and Answers
Question 1: What are the seven questions that form the basis of RCM analysis per SAE JA1011?
- Who, what, when, where, why, how, how much
- Functions, functional failures, failure modes, failure effects, consequences, proactive tasks, default actions (Correct answer)
- Plan, do, check, act, review, improve, sustain
- Design, build, test, implement, operate, maintain, dispose
Correct answer: Functions, functional failures, failure modes, failure effects, consequences, proactive tasks, default actions
RCM answers seven questions in sequence from functions through failure modes, effects, consequences, to task selection.
The sequence is critical: understanding function and context before analyzing failures ensures completeness. Questions cover functions, functional failures, failure modes, failure effects, consequences, proactive tasks, and default actions.
Question 2: How does RCM classify failure consequences?
- By repair cost only
- Into four categories: hidden, safety/environmental, operational, and non-operational (Correct answer)
- By failure frequency
- By equipment age
Correct answer: Into four categories: hidden, safety/environmental, operational, and non-operational
RCM classifies consequences into four categories that determine the maintenance response type.
Hidden consequences require failure-finding tasks. Safety/environmental consequences mandate risk reduction or redesign. Operational consequences require cost-effective proactive tasks. Non-operational consequences justify tasks only if cheaper than repair.
Question 3: What is a functional failure in RCM terminology?
- A failure of any component
- The inability to fulfill a function to an acceptable performance standard (Correct answer)
- A failure during operation
- A failure requiring replacement
Correct answer: The inability to fulfill a function to an acceptable performance standard
A functional failure occurs when an asset cannot perform one or more functions to the minimum required performance standard.
Functional failures are defined relative to functions and performance standards. Each function can have multiple functional failures including total failure and partial failures where degraded performance is unacceptable.
Question 4: What is the RCM decision diagram used for?
- To decide which equipment to purchase
- To systematically select the most appropriate maintenance task for each failure mode (Correct answer)
- To plan production schedules
- To determine employee assignments
Correct answer: To systematically select the most appropriate maintenance task for each failure mode
The RCM decision diagram is a structured logic tree guiding analysts through consequence classification and task selection.
The diagram has three columns: consequence evaluation, proactive task selection, and default actions. It ensures task selection follows consequence priority, each task type is considered before moving to the next.
Question 5: What is the role of operating context in RCM analysis?
- It is not important
- It defines specific conditions affecting function definitions, failure patterns, and consequence severity (Correct answer)
- It only describes physical location
- It determines purchase price
Correct answer: It defines specific conditions affecting function definitions, failure patterns, and consequence severity
The operating context describes the environment, conditions, and requirements that influence how an asset is used and how failures affect operations.
Operating context includes process description, environment, operating regime, performance requirements, redundancy, safety regulations, production schedule, and parts availability. Two identical pumps in different contexts may have entirely different RCM outcomes.
Question 6: What is the difference between scheduled restoration and scheduled discard in RCM?
- There is no difference
- Restoration returns a component to original capability; discard replaces it entirely, both at specified intervals (Correct answer)
- Restoration is always cheaper
- Discard is never appropriate
Correct answer: Restoration returns a component to original capability; discard replaces it entirely, both at specified intervals
Restoration rebuilds a component to original capability; discard replaces it with a new one, both at defined ages.
Both are time-based tasks applicable only when failure probability increases with age (Weibull beta > 1). Restoration involves overhaul; discard involves complete replacement. The technical criterion is an identifiable age at which failure probability increases significantly.
CMRP Reliability-Centered Maintenance Analysis 2
What are the seven questions that form the basis of RCM analysis per SAE JA1011?