DEFSTAN 02-45/2(2000) : 2000

TITLE PAGE
SCOPE
ACKNOWLEDGEMENTS
FOREWORD
Introduction
Conditions of Release
MOD Tender or Contract Process
Categories of NES
Related Document
Health and Safety
Additional Info
The Regulated Environment
CONTENTS
SECTION 1 - RCM IN THE ROYAL NAVY
1.1 Key Players
1.2 Background
1.3 Patterns of Failure
1.4 Summary of the RCM Process
1.5 Training
1.6. Defence Standard 00-60 Correlation
SECTION 2 - THE RCM PROCESS WITHIN ILS
2.1 Key Players
2.2 Introduction
2.3 Background
2.4 Management of RCM within the LSA Process
     2.4.1 Introduction
     2.4.2 LSA Strategy (Task 101)
     2.4.3 LSA Plan (Task 102)
     2.4.4 Programme and Design Reviews (Task 103)
2.5 LSA Process Map
     2.5.1 The RCM RN Software Toolkit
     2.5.2 The RCS RN Software Toolkit
SECTION 3 - THE PLATFORM PROCESS
3.1 Key Players
3.2 Preparatory Work
3.3 RCM Platform Process Map
SECTION 4 - ENGINEERING INFORMATION REQUIREMENTS
4.1 Key Players
4.2 Failure Data
4.3 Useful Documentation
4.4 Templating
     4.4.1 Use of Existing RCM RN FMECA and Task Analysis Data
     4.4.2 Available RCM (RN) Templating Data
4.5 Documentation Amendments
4.6 Defence Standard 00-60 Correlation
SECTION 5 - THE OPERATING CONTEXT
5.1 Key Players
5.2 Requirement
5.3 Platform Level Operating Context (Level 2)
5.4 Engineering Discipline Operating Contexts (Level 3)
5.5 Functional Block and Functional Asset Group (FAG) Operating
     Contexts
5.6 Mission Phase Analysis
5.7 Asset Redundancy
5.8 Operating Context Records
5.9 Defence Standard 00-60 Correlation
SECTION 6 - FUNCTIONAL PARTITIONING
6.1 Key Players
6.2 Functional Partitioning Requirement
6.3 Functional Partitioning Process
6.4 Selection of Functional Blocks for Analysis
     6.4.1 Selection Considerations
     6.4.2 Functional Block Consolidation
6.5 Overall Specification for a Functional Block
6.6 Review of Analysis Boundary Definitions
6.7 Defence Standard 00-60 Correlation
SECTION 7 - COMPOSITION OF THE ANALYSIS TEAM
7.1 Key Players
7.2 Team Considerations
7.3 Marine and Combat System Analyses
7.4 Structural Analyses
7.5 Technical Secretary
7.6 General
7.7 Defence Standard 00-60 Correlation
SECTION 8 - STRUCTURING THE FAILURE MODES, EFFECTS AND
            CRITICALITY ANALYSIS
8.1 Key Players
8.2 Introduction
8.3 Functional Asset Groups (FAGs)
     8.3.1 FAG 0
8.4 Levels of Indenture
     8.4.1 Starting at Too Low a Level
     8.4.2 Starting at the Top
8.5 Choice of Indenture Level
8.6 Defence Standard 00-60 Correlation
SECTION 9 - PROCEDURE FOR CARRYING OUT A FMECA
9.1 Key Players
9.2 Introduction
9.3 PHASE1: Identification of the Functions
     9.3.1 Primary Functions
     9.3.2 Secondary Functions
     9.3.3 Obscure Functions
     9.3.4 Method of Working
9.4 PHASE 2: Functional Failures, Failure Modes, and Failure Effects
     9.4.1 Functional Failures
     9.4.2 Failure Modes
     9.4.3 Failure Effects
           9.4.3.1 Failure Effect Categories
           9.4.3.2 Failure Effect Considerations
     9.4.4 Level of Repair Analysis (LORA)
9.5 PHASE 3: Criticality Assessment
     9.5.1 Criticality Matrix
         9.5.1.1 Use of Generic Assessment Categories
     9.5.2 Use of Non-RCM (RN) FMECA Data
     9.5.3 Considerations when using Non-RCM (RN) FMECA Data
           9.5.3.1 Level of Analysis
           9.5.3.2 Design FMECAs
           9.5.3.3 Detail of Information
     9.5.4 Summary
9.6 Example RCM (RN) Toolkit FMECA Worksheet
9.7 Defence Standard 00-60 Correlation
SECTION 10 - RCM ANALYSIS USING MARINE AND COMBAT SYSTEM
             ENGINEERING ALGORITHM
10.1 Key Players
10.2 Introduction
10.3 Consequences of Failure - Hidden/Evident
10.4 Consequences of Failure - Safety/Environmental, Operational
     or Non-Operational
10.5 Maintenance Tasks
10.6 Maintenance Task Categories
     10.6.1 Option 1: On Condition Tasks
            10.6.1.1 On Condition Task Applicability
            10.6.1.2 On Condition Task Effectiveness
            10.6.1.3 Assessment of the Cost of Performing the
                     On Condition Task
            10.6.1.4 Assessment of the Cost of Allowing the
                     Failure to Occur
     10.6.2 Options 2 and 3: Scheduled Restoration and Discard Tasks
            10.6.2.1 Scheduled Restoration and Discard Task
                      Applicability
            10.6.2.2 Scheduled Restoration and Discard Task
                     Effectiveness
     10.6.3 Option 4: Combination Tasks
10.7 Default Tasks
     10.7.1 Option 5: Failure Finding Tasks
            10.7.1.1 Failure Finding Task Applicability
            10.7.1.2 Failure Finding Task Effectiveness
            10.7.1.3 Calculation of Failure Finding Intervals
            10.7.1.4 Failure Finding Task Availability Requirements
     10.7.2 Option 6: No Scheduled Maintenance
     10.7.3 Option 7: Redesign
10.8 Other Actions
     10.8.1 Option 8: Part of Ship Plan
            10.8.1.1 Rounds and System Operator Checks
     10.8.2 Option 9: Age Exploration (AE)
            10.8.2.1 AE Priorities
            10.8.2.2 Use of AE Data
10.9 Consolidating Study Maintenance Tasks (Task Linking)
10.10 Defence Standard 00-60 Correlation
SECTION 11 - RCM ANALYSIS OF STRUCTURES AND STRUCTURAL ITEMS
11.1 Key Players
11.2 Introduction
11.3 Complex Structure
     11.3.1 Load Bearing Structure
     11.3.2 Containment
     11.3.3 Other Functions
11.4 Structural Failure Categories
     11.4.1 Fatigue Damage (FD)
     11.4.2 Environmental Deterioration (ED)
     11.4.3 Accidental Damage (AD)
11.5 Structural Survey and Monitoring
11.6 The Structural Analysis Process
     11.6.1 Identification of Analysis Boundary
     11.6.2 Operating Context
     11.6.3 Categorisation of Structure
     11.6.4 Significant Structure and Structurally Significant Items
            11.6.4.1 Significant
            11.6.4.2 Other Structure
     11.6.5 Identification of Structurally Significant Items
            11.6.5.1 Consolidation of SSIs for Analysis
            11.6.5.2 Structural Failure Modes Effects and Criticality
                     Analysis
     11.6.6 Safe Life (SL)/Damage Tolerant (DT) Assessment
            11.6.6.1 Safe Life Definition
            11.6.6.2 Damage Tolerant Definition
11.7 Data Analysis
     11.7.1 Fatigue Damage Analysis
            11.7.1.1 Safe Life Analysis
            11.7.1.2 Damage Tolerant Analysis
     11.7.2 Environmental Deterioration Analysis
            11.7.2.1 Stage One
            11.7.2.2 Stage Two
            11.7.2.3 Stage Three
     11.7.3 Threat Reduction Effect of Cathodic Protection
     11.7.4 Accidental Damage Analysis
            11.7.4.1 Damage Tolerant Structures
            11.7.4.2 Safe Life Structure
            11.7.4.3 Accidental Damage Risk Assessment
            11.7.4.4 The AD Task Interval
            11.7.4.5 Damage Tolerant Structure - Accidental Damage
                     Task Interval
            11.7.4.6 Safe Life Structure - Accidental Damage
                     Task Interval
     11.7.5 Deriving the Natural Inspection Interval
     11.7.6 Influence of Build and Design Quality (B&DQ)
11.8 Age Exploration Considerations
11.9 Applying the RCM Algorithm
     11.9.1 On Condition Tasks
     11.9.2 Discard Tasks
11.10 Compiling the Structural Inspection Plan
      11.10.1 Directed Inspections
      11.10.2 Part of Ship Plan (PSP)
11.11 Analysis of non-Metallic Structural Materials
11.12 Defence Standard 00-60 Correlation
SECTION 12 - MAINTENANCE SCHEDULES AND JOB INFORMATION CARDS
12.1 Key Players
12.2 General
12.3 Job Information Cards
12.4 Production of Bullet Point Job Information Cards
12.5 Finalised Job Information Cards
12.6 Personnel Safety Assessments
     12.6.1 As Low As Reasonably Practicable (ALARP)
     12.6.2 Personnel Risk Safety Assessments
     12.6.3 Risk/Hazard Control Strategy
12.7 Maintenance Schedules
12.8 Defence Standard 00-60 Correlation
SECTION 13 - TASK RATIONALISATION AND DERIVATION OF THE PLATFORM
             UPKEEP CYCLE
13.1 Key Players
13.2 Introduction
13.3 Rationalisation of Maintenance Schedules
     13.3.1 Maintenance Task Category Grouping
     13.3.2 Rationalisation Rules
13.4 Individual Study Rationalisation
13.5 Upkeep Cycle Derivation
13.6 Recording Rationalised Task Intervals
13.7 Spares
13.8 Management of the Royal Navy Vessels within an RCM
     Derived Upkeep Cycle
13.9 Defence Standard 00-60 Correlation
SECTION 14 - SPARES HOLDING DETERMINATION
14.1 Key Players
14.2 General
14.3 The RCS Process
14.4 Defence Standard 00-60 Correlation
SECTION 15 - AUDITING
15.1 Key Players
15.2 Purpose
15.3 Audit Definitions
15.4 Audit Guidelines
15.5 Defence Standard 00-60 Correlation
ANNEX A - RELATED DOCUMENTS
ANNEX B - ABBREVIATIONS AND DEFINITIONS
ANNEX C - THE RCM RN TOOLKIT
ANNEX D - THE RCS RN TOOLKIT
ANNEX E - RCM IN REGULATED AND/OR CONTROLLED ENVIRONMENTS
ANNEX F - FUNCTIONAL PARTITIONING AND OBSCURE FUNCTIONS
ANNEX G - OPERATING CONTEXT FORMATS
ANNEX H - REQUIREMENTS FOR WRITING JOB INFORMATION CARDS (JICs)

Gives guidance on how to prepare for, conduct and utilise the results of Reliability Centred Maintenance (RCM) analyses.