RELIABILITY CENTRED MAINTENANCE PROGRAM (RCM)

The RCM programme is used to determine the maintenance requirements of  any physical asset in its operating context. RCM preserves asset function as   compared to preserving the equipment itself based on the criticality of the  plant.

When implemented, RCM streamlines the asset's preventive maintenance   schedule tasks, thereby reducing costs without compromising on safety and   availability.

RCM at Lumut Power Plant (LPP)

The Reliability Centred Maintenance (RCM) Programme at LPP was   successfully implemented in the year 2000. The RCM project has covered   almost 90% of the total assets in LPP. In the project, 10 teams were formed   and each of them was assigned with 3 sub-systems to be analysed and   completed within a year.

The outcome of the RCM analysis i.e. the Planned Maintenance (PM) tasks   have been scheduled and incorporated in the SAP R/3 system. The PM tasks  included all the identified Inspection, Predictive (Condition Based   Maintenance-CBM) and Preventive type of maintenance. By incorporating   the tasks in SAP system, TJSB will ensure that the RCM based tasks will be   religiously and disciplinely followed and executed to ensure that the   objective  of RCM can be realised.

A report to measure the effectiveness and efficiency of the PM task is   generated every monthly which is part of Maintenance Performance   Indicators. From here, the PM tasks adequacy would be reviewed as part of   continuous improvement effort and be amended if need be. This review   would   be done by 5 teams called PAC (Plant Area Concept) team, based  on the system they owned.