SAE JA 1012-2011 A Guide to the Reliability-Centered Maintenance (RCM) Standard《以可靠性为中心的维护(RCM)标准指南》.pdf

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1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there

2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2010 SAE International All rights reserved. No part of this publication m

3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside U

4、SA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/JA1012_201108SURFACE VEHICLE/AEROSPACERECOMMENDEDPRACTICEJA1012 AUG2011 Issued 2002-01 Revised

5、2011-08 Superseding JA1012 JAN2002 A Guide to the Reliability-Centered Maintenance (RCM) Standard RATIONALE The document was updated as a result of the normal 5 year review cycle and to maintain consistency with the most recent revisions to SAE JA1011 Evaluation Criteria for Reliability-Centered Mai

6、ntenance (RCM) Processes. Changes were made to clarify the origin of the Reliability Centered Maintenance process and purpose of that document. Additionally, terminology was updated to reflect current usage in the user community and to remove items that might have been considered biased to individua

7、l commercial processes. The overall technical process remains unchanged. FOREWORD Reliability-Centered Maintenance (RCM) was first documented in a report written by F.S. Nowlan and H.F. Heap of United Airlines and published by the U.S. Department of Defense in 1978. It described the then-current sta

8、te-of-the-art processes used to develop maintenance programs for commercial aircraft. Since then, the RCM process has been widely used by other industries, and has been extensively refined and developed. These refinements have been incorporated into numerous application documents, published by a var

9、iety of organizations around the world. Many of these documents remain faithful to the basic principles of RCM as expounded by Nowlan and Heap. However in the development of some of these documents, key elements of the RCM process have been omitted or misinterpreted. Due to the growing popularity of

10、 RCM, other processes have emerged that have been given the name “RCM” by their proponents, but that are not based on Nowlan and Heap at all. While most of these processes may achieve some of the goals of RCM, a few are actively counterproductive, and some are even dangerous. As a result, there has

11、been a growing international demand for a standard that sets out the criteria that any process must comply with in order to be called “RCM.” SAE JA1011 meets that need. However SAE JA1011 presupposes a high degree of familiarity with the concepts and terminology of RCM. This Guide amplifies, and whe

12、re necessary clarifies, those key concepts and terms, especially those that are unique to RCM. Note that this Guide is not intended to be a manual or a procedural guide for performing RCM. Those who wish to apply RCM are strongly encouraged to study the subject in greater detail, and to develop thei

13、r competency under the guidance of experienced RCM practitioners. SAE JA1012 Revised AUG2011 Page 2 of 62 TABLE OF CONTENTS 1. SCOPE 41.1 Organization of the Guide . 42. REFERENCES 42.1 Applicable Publications . 42.2 Related Publications . 42.3 Other Publications . 53. DEFINITIONS . 64. ACRONYMS . 9

14、5. ASSET DEFINITION . 96. FUNCTIONS . 96.1 Operating Context . 106.2 List of Functions 116.3 Describing Functions . 136.4 Performance Standards 147. FUNCTIONAL FAILURES. 157.1 Partial and Total Failure 167.2 Upper and Lower Limits 168. FAILURE MODES . 168.1 Identifying Failure Modes 178.2 Establishi

15、ng What Is Meant By “Reasonably Likely” 188.3 Levels of Causation . 188.4 Sources of Information about Failure Modes 208.5 Types of Failure Modes . 219. FAILURE EFFECTS 219.1 Basic Assumptions 229.2 Information Needed . 2210. FAILURE CONSEQUENCE CATEGORIES . 2410.1 Consequence Categories . 2410.2 As

16、sessing Failure Consequences . 2811. FAILURE MANAGEMENT POLICY SELECTION 2811.1 The Relationship Between Age and Failure . 2811.2 Technically Feasible and Worth Doing . 2911.3 Cost Effectiveness 2911.4 Failure Management Policy Selection . 3012. FAILURE CONSEQUENCE MANAGEMENT . 3012.1 Evident Failur

17、e Modes with Safety or Environmental Consequences 3012.2 Hidden Failure Modes with Safety or Environmental Consequences . 3212.3 Evident Failure Modes with Economic Consequences . 3312.4 Hidden Failure Modes with Economic Consequences . 3413. FAILURE MANAGEMENT POLICIESSCHEDULED TASKS 3413.1 On-Cond

18、ition Tasks 3413.2 Scheduled Restoration and Scheduled Discard Tasks . 4013.3 Failure-finding Tasks . 4113.4 Combination of Tasks . 46SAE JA1012 Revised AUG2011 Page 3 of 62 14. FAILURE MANAGEMENT POLICIESONE-TIME CHANGES AND RUN-TO-FAILURE 4614.1 One-Time Changes . 4614.2 Run To Failure 4915. FAILU

19、RE MANAGEMENT POLICY SELECTION 4915.1 Two Approaches . 4915.2 The Rigorous Approach 5015.3 Decision Diagram Approaches . 5116. A LIVING PROGRAM . 5617. MATHEMATICAL AND STATISTICAL FORMULAE 5717.1 Logically Robust 5717.2 Available to Owner or User . 5718. IMPORTANT ADDITIONAL CONSIDERATIONS . 5818.1

20、 Prioritizing assets and establishing objectives 5818.2 Planning 5918.3 Level of Analysis And Asset Boundaries 5918.4 Technical Documentation . 6018.5 Organization 6018.6 Training . 6118.7 Role of computer software 6118.8 Data gathering . 6118.9 Implementation 6219. NOTES 62FIGURE 1 FUNCTION OF A PU

21、MP . 13FIGURE 2 ALLOWING FOR DETERIORATION 14FIGURE 3 FAILURE MODES OF A PUMP 17FIGURE 4 FAILURE MODES AT DIFFERENT LEVELS OF DETAIL . 19FIGURE 5 EVIDENT FAILURE OF A PROTECTIVE FUNCTION . 25FIGURE 6 HIDDEN FAILURE OF A PROTECTIVE FUNCTION . 26FIGURE 7 SIX PATTERNS OF FAILURE 29FIGURE 8 THE P-F CURV

22、E . 35FIGURE 9 THE P-F INTERVAL 35FIGURE 10 NET P-F INTERVAL 36FIGURE 11 RANDOM FAILURES AND THE P-F INTERVAL . 37FIGURE 12 A LIINEAR P-F CURVE 38FIGURE 13 INCONSISTENT P-F INTERVALS . 39FIGURE 14 SAFE LIFE LIMITS 41FIGURE 15 FAILURE-FINDING INTERVAL, AVAILABILITY, AND RELIABILITY 44FIGURE 16 FIRST

23、DECISION DIAGRAM EXAMPLE . 54FIGURE 17 SECOND DECISION DIAGRAM EXAMPLE 55SAE JA1012 Revised AUG2011 Page 4 of 62 1. SCOPE SAE JA1012 (“A Guide to the Reliability-Centered Maintenance (RCM) Standard”) amplifies and clarifies each of the key criteria listed in SAE JA1011 (“Evaluation Criteria for RCM

24、Processes”), and summarizes additional issues that must be addressed in order to apply RCM successfully. 1.1 Organization of the Guide Sections 5 to 14, 16, and 17 of this Guide reflect the major sections of SAE JA1011. Section 15 explains in more detail how key elements of the RCM process can be co

25、mbined to select appropriate policies for managing individual failure modes and their consequences. Section 18 addresses management and resourcing issues essential to the successful performance of RCM. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specificatio

26、n to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae

27、.org.SAE JA1011 Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report.2.2.1 U.S. Department of Commerce Publication Available fro

28、m NTIS, Port Royal Road, Springfield, VA 22161. Nowlan, F. Stanley, and Howard F. Heap, “Reliability-Centered Maintenance,” Department of Defense, Washington, D.C. 1978, Report Number AD-A066579 SAE JA1012 Revised AUG2011 Page 5 of 62 2.2.2 U.S. Department of Defense Publications Available from DODS

29、SP, Subscription Services Desk, Building 4/Section D, 700 Robbins Avenue, Philadelphia, PA 19111-5098. MIL standards and handbooks may also be obtained from https:/assist.daps.dla.mil/quicksearch/.MIL-HDBK 2173(AS) ”Reliability-Centered Maintenance Requirements for Naval Aircraft, Weapons Systems an

30、d Support Equipment,” (U.S. Naval Air Systems Command) (NOTE: canceled without replacement, August 2001.) NAVAIR 00-25-403 ”Guidelines for the Naval Aviation Reliability-Centered Maintenance Process,” (U.S. Naval Air Systems Command) MIL-P-24534 ”Planned Maintenance System: Development of Maintenanc

31、e Requirement Cards, Maintenance Index Pages, and Associated Documentation,” (U.S. Naval Sea Systems Command) MIL-STD-1629 “Procedures for Performing a Failure Mode, Effects and Criticality Analysis,” Department of Defense, Washington, DC, 1984 (NOTE: Cancelled without replacement, August 1998) MIL-

32、STD-1843 “Reliability Centered Maintenance for Aircraft, Engines, and Equipment,” United States Air Force (NOTE: Cancelled without Replacement, August 1995) S9081-AB-GIB-010/MAINT ”Reliability-Centered Maintenance Handbook” (U.S. Naval Sea Systems Command) 2.2.3 U.K. Ministry of Defence Publication

33、Available from Reliability-centred Maintenance Implementation Team, Ships Support Agency, Ministry of Defence (Navy), Room 22, Block K, Foxhill, Bath, BA1 5AB, United Kingdom. NES 45 ”Naval Engineering Standard 45, Requirements for the Application of Reliability-Centred Maintenance Techniques to HM

34、Ships, Royal Fleet Auxiliaries and other Naval Auxiliary Vessels” (Restricted-Commercial) 2.3 Other Publications The following publications were consulted in the course of developing this SAE Technical Report and are not a required part of this document. Anderson, Ronald T. and Neri, Lewis, “Reliabi

35、lity-Centered Maintenance: Management and Engineering Methods,” Elsevier Applied Science, London and New York, 1990 Blanchard, B.S., D. Verma and Peterson, E.L., “Maintainability: A Key to Effective Serviceability and Maintenance Management,” John Wiley and Sons, New York, 1995 “Dependability Manage

36、ment - Part 3-11: Application guide - Reliability centred maintenance,” International Electrotechnical Commission, Geneva, Doc. No. 56/651/FDIS Jones, Richard B., “Risk-Based Management: A Reliability-Centered Approach,” Gulf Publishing Co., Houston, TX, 1995 MSG-3, Maintenance Program Development D

37、ocument,” Air Transport Association, Washington, D.C. Revision 2007.1 Moubry, John, “Reliability Centered Maintenance,” Industrial Press. Inc. New York City, 1997. Smith, Anthony M., “Reliability Centered Maintenance,” McGraw-Hill, New York. 1993 Zwingelstein, G., “Reliability Centered Maintenance,

38、a practical guide for implementation,” Herms, Paris. 1996 SAE JA1012 Revised AUG2011 Page 6 of 62 3. DEFINITIONS 3.1 AGE A measure of exposure to stress computed from the moment an item enters service or first begins to degrade, either from new or re-entering service after a task designed to restore

39、 its initial capability. Age can be measured in terms of calendar time, running time, distance traveled, duty cycles, or units of output or throughput. 3.2 APPROPRIATE TASK A task that is capable of preventing or mitigating the consequences of failure based on the technical characteristics of that f

40、ailure3.3 CONDITIONAL PROBABILITY OF FAILURE The probability that a failure will occur in a specific period provided that the item concerned has survived to the beginning of that period. 3.4 DESIRED PERFORMANCE The level of performance desired by the owner or user of a physical asset or system. 3.5

41、ENVIRONMENTAL CONSEQUENCES A classification assigned to failure modes, or multiple failures in the case of hidden failure modes, that could result in a breach of any industry or government environmental standard or regulation. 3.6 EVIDENT FAILURE A failure mode whose effects become apparent to the o

42、perator(s)under normal circumstances if the failure mode occurs on its own. 3.7 EVIDENT FUNCTION A function whose failure on its own becomes apparent to the operator(s)under normal circumstances. 3.8 FAILURE CONSEQUENCES A classification of the failure effects of failure modes into categories based

43、on evidence of failure, impact on safety, the environment, operational capability, and cost. 3.9 FAILURE EFFECT What happens when a failure mode occurs. 3.10 FAILURE-FINDING TASK A scheduled task used to determine whether a specific hidden failure has occurred. 3.11 FAILURE MANAGEMENT POLICY A gener

44、ic term that encompasses on-condition tasks, scheduled restoration, scheduled discard, failure-finding, run-to-failure, and one-time changes. SAE JA1012 Revised AUG2011 Page 7 of 62 3.12 FAILURE MODE A single event, which causes a functional failure. 3.13 FUNCTION What the owner or user of a physica

45、l asset or system wants it to do. 3.14 FUNCTIONAL FAILURE A state in which a physical asset or system is unable to perform a specific function to a desired level of performance. 3.15 HIDDEN FAILURE A failure mode whose effects do not become apparent to the operator(s) under normal circumstances if t

46、he failure mode occurs on its own. 3.16 HIDDEN FUNCTION A function whose failure on its own does not become apparent to the operator(s) under normal circumstances. 3.17 INITIAL CAPABILITY The level of performance that a physical asset or system is capable of achieving at the moment it enters service

47、. 3.18 MULTIPLE FAILURE An event that occurs if a protected function fails while its protective device or protective system is in a failed state. 3.19 NET P-F INTERVAL The minimum interval likely to elapse between the discovery of a potential failure and the occurrence of the functional failure. 3.2

48、0 NON-OPERATIONAL CONSEQUENCES A classification assigned to failure modes that do not adversely affect safety, the environment, or operations, but only require repair or replacement of any item(s) that may be affected by the failure. 3.21 ON-CONDITION TASK A periodic or continuous task used to detec

49、t a potential failure. 3.22 ONE-TIME CHANGE Any action taken to change the physical configuration of an asset or system (redesign or modification), to change the method used by an operator or maintainer to perform a specific task, to change the operational context of the system, or to change the capability of an operator or maintainer (training). 3.23 OPERATING CONTEXT The circumstances in which a physical asset or system is expected to o