Free RCM Resources

Secure management commitment and sponsorship

RCM requires resources and time. Get executive buy-in before starting.

Select pilot system/equipment for initial analysis

Choose something important enough to matter, but contained enough to finish.

Assemble cross-functional analysis team

Include operators, maintainers, engineers, and subject matter experts.

Gather existing documentation (P&IDs, manuals, maintenance history)

Historical failure data is gold. Collect everything you can find.

Train team on RCM methodology

Everyone should understand the seven questions and decision logic.

Define operating context and boundaries

Specify load, environment, duty cycle, and interfaces with other systems.

Establish performance standards

What output/quality/rate defines "working properly"?

Identify regulatory and safety requirements

List any codes, standards, or legal requirements that apply.

List all functions (primary and secondary)

Don't forget secondary functions: containment, appearance, safety devices.

Define performance standards for each function

Quantify where possible: flow rate, pressure, temperature, etc.

Identify hidden functions

Protective devices and standby equipment have hidden functions.

Identify all ways each function can fail

Total loss, partial loss, over-performance are all functional failures.

Document functional failure descriptions

Be specific: "Fails to deliver at least 100 L/min" not just "pump fails".

Identify failure modes for each functional failure

What physical events could cause each functional failure?

Describe failure effects (local, system, plant)

Describe what happens: evidence, safety impact, operational impact.

Assess failure consequences (S/E/O/N)

Safety, Environmental, Operational, or Non-operational consequences?

Document in FMEA worksheet format

Use a standardized template to ensure consistency.

Apply RCM decision logic to each failure mode

Work through the decision diagram systematically for each mode.

Select appropriate maintenance tasks

Condition-based, scheduled, failure-finding, or redesign.

Define task intervals and procedures

Base intervals on P-F interval, cost analysis, or acceptable risk.

Identify any redesign requirements

Some failure modes can't be managed by maintenance alone.

Develop maintenance procedures

Turn task decisions into actionable work instructions.

Load tasks into CMMS/EAM system

Create PM work orders with proper intervals and resources.

Train maintenance technicians

Explain the "why" behind tasks, not just the "what".

Communicate changes to operations

Operators need to understand new monitoring and inspection activities.

Establish review triggers (failures, modifications, time)

RCM is not "set and forget" - schedule periodic reviews.

Track key metrics (failures, costs, availability)

Measure to prove the program is working.

Update analysis based on operating experience

Real-world data should refine your failure mode list and intervals.

Expand to additional systems

Use lessons learned to improve the process for future analyses.