How to Complete the RCM3™ Information Worksheet
The Information Worksheet documents the Functions, Failed States, Failure Mode Causes, Mechanisms, Failure Effects, and Inherent Risks. The information worksheet is similar to the Failure Modes, Effects and Criticality Analysis (FMECA) where the severity of the Failure Mode is determined as if nothing was preventing it from occurring.
- The "Analysis Summary" section will be collapsed as it contains complete information carried over from previous steps.
- Expand the Location tree and select the analysis that you have just created.
- Enter the "Function" in the Function Details section.
- Click the "Add Single Function" button if you only wish to add one Function. The Failed State section of the tree will then be expanded for the user to capture the Failed States.
- If a "Function" already exists, the user can select it on the tree, "Update" it and click the main Save button on the top action bar.
- It is possible to add more than one Function to an analysis. To do this, select the analysis on the tree and click the "Add Another Function" button. The number of Functions added will be indicated by a number next to the Function as illustrated below. The user will then have to select the Function in the tree to add the Failed States.
- Capture the "Failed State" in the Failed State Details section.
- Click the "Add Single Failed State" button and the Failed State will be added to the tree and linked to the "Function". The Failure Mode Details section will be expanded for the user to capture the Failure Mode Cause and Mechanism.
- Select an existing Failed State from the tree and Click "Update" if you wish to update a Failed State.
- Similar to the Functions, users can add more than one Failed State by selecting the "Add Another Failed State" button. The number of Failed States will be indicated by a letter next to the Sailed State as illustrated below.
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- The Failed State on the tree must be selected to be able to complete the Failure Mode Details section.
- Expand the Failure Mode Details section and select the "Failure Mode Cause" from the dropdown. This is information populated in the Base file.
- The user can also "Create" a new Failure Mode Cause by typing it in the space provided.
- Click "Create" and the new Failure Mode Causes will be added to the Base file and in the tree.
- To "Update" an existing Failure Mode Cause, select it on the tree and make the necessary changes.
- Select "Update" and the changes will be reflected in the tree.
- Select a "Failure Mechanism" from the dropdown list.
- User can also "Create" a new Failure Mechanism by typing it in the space provided.
- Click Create and the new Failure Mechanism will be added to the tree.
- To "Update" an existing Failure Mechanism, select it on the tree and make the necessary changes.
- Click Update and the changes will be reflected on the tree.
- Select the appropriate Failure Pattern (if known).
- Select the "FM Location ID" if available. The FM Location ID is a drop down of the Analysis Location ID and all child locations. The Failure Mode (FM) Location ID is used to register lower level (child) locations against secondary functions at any lower level that is registered in the asset hierarchy. The system defaults to the Analysis Location ID but can be changed by the user in the base files.
- Click the main Save button on the top action bar to or right click and Save.
OR
How to analyze a Failure Mode Separately
- Select the Analyzed separately box if you wish to create a new analysis for the specific Failure Mode.
- Capture the reason for a separate analysis. If a Failure Mode is identified but is part of a system/sub-system which is outside the boundary of the current analysis, For example, the outside system provides power so losing power could be a Failure Mode for which the user wants to identify the effects but there is no need to broaden the analysis to all the ways that will cause power failures. In this case, the user would identify loss of power as a Failure Mode to document in the analysis, but the analysis does not document all the ways power can be lost. The advantage is that the group continues to focus on the asset and that expertise to analyze outside systems is not needed.
- "The Local Effect, Next Higher-Level Effect, End Effect" boxes will disappear once the "Analyzed Separately" box has been ticked. It is however important to remember that the analysis of the other system needs to be scheduled and tracked since the other system’s integrity impacts the integrity and reliability of the system being analyzed.
Capturing the Failure Effects
Local Effect – This field is a free text field used to register the description of the Local Effect of the Failure Mode on the component.
Next Higher-Level Effect – This field is used to register the description of the effect that the Failure Mode will have on the system of which the component is a part.
End Effect – This field is used to register the description of the effect that the Failure Mode will have on the process and business.
- Select the type of "Failure Mode" using the radio buttons.
- None - This is a button to indicate that the failure mode is not a protected function or a protective device. When this box is checked, the field for potential worst case will not be displayed for population.
- Protected Function – This button indicates whether the failure mode being analyzed is associated with a protected function. When this button is selected, the system will automatically open the Potential Worst-Case Field and the Risk Assessment Fields for population. A protected function is a function that is protected by other device(s) that will take over from the function that has failed i.e., redundant system, backup or standby system.
- Hidden Failure - This is a check box to indicate whether the Failure Mode being analyzed is associated with a protective device. When this button is selected, the system will not open the Potential Worst-Case Field or the Risk Assessment Fields for population.
How to Add “Downtime Details”
This section is used to determine the cost of breakdown without any interaction. The three sections for downtime costs are due to downtime that is based on the downtime cost/hour entered in the “Operating Context”, but it can be changed.
- Enter the downtime hours and the % of production lost (100% being total loss).
- Identify the corrective labor and material costs to get the total costs of breakdown.
How to add a Risk:
Once the Functional Failures, Failure Modes and Failure Effects have been identified, the next step is to determine what risks are associated with each Failure. Once the “Risk” has been identified, one must determine the effect (Consequence) of the “Risk” and the likelihood (Probability) of the event actually taking place.
The “Risk Matrix” assists in determining whether the “Risk” can be reduced or eliminated. In this section, the user captures the unmitigated risk by selecting the loss type, consequence, and probability if nothing was done to prevent the failure.
Note: Only the maximum or controlling risk is identified.
There are two ways in which this section can be completed:
- Using the Shortcut
- Manually completing the Risk Matrix
Option 1. The Shortcut
- Expand the Inherent Risk section.
- Click "Select From Risk Matrix" and a pop-up will appear.
- Select the "Show Probability" radio button.
- Choose a Probability and the Risk Ranking and Consequence will automatically also be captured in the main screen.
- If the "Show Consequence" radio button is selected, the Consequence and "Loss Type" will automatically be captured in the main screen. This means that the user must still select the Probability following the steps above for selecting a Probability.
Option 2: Manually completing the Risk Matrix
- Select the "Probability" from the dropdown menu. Depending on the selection, the "Probability Description" will automatically be added.
- Select a “Consequence" from the dropdown menu. ACTOR will provide a Risk Ranking in line with the Risk Matrix that was developed in the base file.
- Select a “Loss Type” from the dropdown menu. The "Loss Type Consequence" will automatically be added.
- The Operating Context Images will be carried over from the Operating Context.
- Capture “Comments” if necessary, in the "Notes Details" section.
- Click “Save”.
After the Functions, Failed States, Failure Causes, Mechanisms, Effects and Inherent Risks are completed, the RCM3™ Decision Diagram is used to guide toward a failure management strategy. The user answers all questions based upon the Failure Cause, Mechanisms and the Failure Effects completed on the Information Worksheet in previous steps.
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