SpecTek helped to implement RCM at the Chelyabinsk Metallurgical Plant
Specialists of "Spetstek" provided consulting services on the implementation of a reliability-centered approach to equipment maintenance in "Chelyabinsk Metallurgical Combine".
Reliability-Centered Maintenance (RCM) is a methodology for selecting applicable and effective equipment failure management policies and forming a work program from them that combines various maintenance and repair strategies (MRO) and meets the profile of risks associated with failures.
The basic idea of RCM is that the rules of equipment maintenance should be determined by the consequences of failure, and not only by the nature and parameters of failure. The same equipment does not mean the same service, since two identical pieces of equipment may have different significance for production and therefore different consequences of failure, and have different operating conditions.
The reliability-oriented approach allows us to determine the optimal set and frequency of actions that must be performed in order for the equipment to continue to do what is required of it under given conditions.
To implement such an approach, Chelyabinsk Metallurgical Combine attracted consultants from "Spetstek", who conducted introductory training courses, performed an audit of the current MRO system and on this basis developed regulatory and methodological documents and conducted practical exercises on their application.
The introductory training program included the courses "MRO Planning" (16 hours) and "Reliability" (40 hours) of an educational nature, which provided the project participants with a single conceptual apparatus and a common understanding of the goals and objectives of the project.
During the audit, specialists of "Spetstek" studied the current MRO system, identified inconsistencies and, based on the results, made recommendations for corrective actions and the development of the MRO system. In particular, functional and technical requirements for the MRO management information system have been developed. A target model has been developed for the transformation of the MRO system into a system of maintenance, repair and reliability assurance (SMRR), which determines how the RCM methodology should be applied as part of MRO processes, taking into account the ideas and principles of asset management set out in the ISO 55000 series standards.
For regulatory support of this model, a top-level document (enterprise standard) "MRO and Reliability Assurance System" has been developed, regulating the activities of senior management, service managers and specialists of structural divisions involved in the SMRR processes. In turn, to ensure its application, a set of techniques has been developed, of which the "RCM Process" methodology is at the upper level, and at the subordinate (providing) level – the methods "Determination of equipment criticality", "Calculation of life cycle cost", "Calculation of the technical condition index", "Analysis of root causes of failure", "KPI system for analyzing reliability/efficiency of MRO".
In order to develop the skills of practical application of these techniques, two seminars were held, within the framework of which their participants were given individual tasks to work out these techniques on three specified units of equipment. At the end of this work, each participant of the seminar presented their results in the presence of the company's management.