To implant a RCM program requires some steps to ensure its feasibility, we must keep in mind that this program is included in a full continuous improvement plan that must be sustainable in the long-temp.
These steps could be:
1. Creating a reliability culture, from the senior management to all levels of the organization. This culture should have the expressed support from the executive direction and should focus on the benefits for the company as a whole. It can start by trainings, conferences, workshops and promotional campaigns.
2. Developing a project team, it can include the following roles:
a. A Sponsor sponsors the project and gives authorities (e.g. an executive manager).
b. A Project Manager stablishes a strategy, a planning with milestones, and a control plan (e.g. the maintenance manager).
c. A RCM Leader manages the project, communicates results, ensures deadlines, and monitors the project development (e.g. the reliability engineer).
d. A RCM Facilitator, with an expertise in the methodology, facilitates analysis process and ensures the project makes progress according to process through the introduction of best practices (an external consultant is recommended).
e. A RCM Team develops the analysis according to the methodology and the strategy of the project, it can perform audits and analysis reviews or a specific team for audits and reviews can be needed; the team should be multidisciplinary and include members of maintenance, operations, and planning departments, even it can include external advisers or vendor representatives.
f. A RCM Implantation Team can be formed by members of the RCM Team specialized in the start-up of the process.
3. Establishing targets and strategies, in accordance with organization goals, vision, mission and strategy.
4. Performing the RCM analysis, in accordance with the methodology and the selected logic tree, to perform the analysis in the plant as a whole but the process must start with the more critical equipment or with the worst actors.
5. Implementing the RCM analysis, in the selected equipment, including the tasks and actions definitions, coordinating with other departments of the organization and stakeholders, defining procedures, collecting data, and calculating key performance indicators; this function can be done in parallel with new RCM analysis.
6. Checking and analyzing results, based in indicators defined and implanted during the analysis, benefits are assessed, and any variation in the expected results should be analyzed by root cause analysis process.
7. Keeping with the RCM plan, the plan must go on indefinitely, reviewing indicators, analyzing failure data, updating procedures and training programs, monitoring results, and updating the RCM program in according with changes in the work conditions and the latest technologies, so that the reliability improvements and the cost savings can be sustained in the long-temp.