RELIABILITY-CENTERED MAINTENANCE (RCM) CHECKLIST

Created by ChecklistGuro (https://checklistguro.com)

--- ASSET IDENTIFICATION & SCOPE DEFINITION ---
[ ] Asset Name/Designation
[ ] Asset ID / Serial Number
[ ] Brief Description of Asset and its Purpose in Manufacturing
[ ] Asset Location within the Manufacturing Facility
[ ] Criticality Ranking (High, Medium, Low) (High, Medium, Low)
[ ] Date of Last Major Overhaul/Replacement
[ ] List of Connected Systems / Interdependencies
[ ] Asset Status (Operational, Out-of-Service, Decommissioned) (Operational, Out-of-Service, Decommissioned)

--- FUNCTIONAL ANALYSIS ---
[ ] Describe the primary function(s) of the equipment in the manufacturing process.
[ ] Describe the secondary or supporting functions of the equipment.
[ ] What is the criticality of this equipment to production? (Critical - Production Halt if Failure, Major - Significant Production Impact, Moderate - Minor Production Impact, Low - Minimal Production Impact)
[ ] Estimated Production Output (Units/Hour) if equipment is functioning normally.
[ ] List any dependencies the equipment has on other systems or processes.
[ ] Is the equipment part of a critical safety system? (Yes, No)
[ ] Describe any regulatory or compliance requirements related to the equipmentâ€™s function.

--- FAILURE MODE IDENTIFICATION ---
[ ] Describe the Potential Failure Mode
[ ] Failure Mode Category (e.g., Mechanical, Electrical, Hydraulic) (Mechanical, Electrical, Hydraulic, Pneumatic, Software/Control, Other)
[ ] Estimated Frequency of Failure Mode (per year)
[ ] Initial Severity of Failure Mode (Impact on Process) (Catastrophic, Critical, Major, Moderate, Minor)
[ ] Describe any visible indicators or warning signs of this failure mode
[ ] Which components are directly involved in this failure mode?

--- FAILURE EFFECT ANALYSIS ---
[ ] Describe the Impact on Production Output
[ ] Describe the Impact on Product Quality
[ ] Describe the Impact on Safety (Personnel and Environment)
[ ] Describe the Impact on Other Equipment or Processes
[ ] Estimated Downtime (hours) due to this failure mode
[ ] Estimated Cost of Production Loss (USD) due to this failure mode
[ ] Estimated Cost of Repair/Replacement (USD)
[ ] Severity Ranking (1-Critical, 5-Minor) (1 - Critical, 2 - Major, 3 - Moderate, 4 - Minor, 5 - Negligible)

--- FAILURE CAUSE IDENTIFICATION ---
[ ] Describe the primary cause of the failure mode.
[ ] Select all contributing factors to the failure (e.g., environment, operator error, material defect). (Environmental Conditions (Temperature, Humidity, Vibration), Lubrication Issues, Operator Error/Training, Material Degradation, Design Flaw, Installation Error, Power Supply Issues, Incorrect Part/Component, Other (Specify in LONG_TEXT))
[ ] Estimated Frequency of Root Cause Occurrence (e.g., times per year)
[ ] Describe any historical data or past incidents that support the identified root cause.
[ ] Severity of Root Cause (Impact on overall system failure) (Critical, Major, Moderate, Minor)
[ ] Upload any supporting documentation (e.g., maintenance logs, inspection reports, test results).
[ ] Describe the current level of control or mitigation for this root cause (if any).

--- MAINTENANCE TASK SELECTION ---
[ ] Primary Maintenance Task Type? (Time-Based Maintenance (Preventive), Condition-Based Maintenance (Predictive), Run-to-Failure (RTLF), Criticality-Based Maintenance)
[ ] Task Frequency (if Time-Based)
[ ] Task Description & Procedure
[ ] Condition Monitoring Method (if Condition-Based) (Vibration Analysis, Infrared Thermography, Oil Analysis, Ultrasonic Testing, Motor Current Signature Analysis (MCSA), None)
[ ] Condition Threshold Limit
[ ] Initial Task Implementation Date
[ ] Skills Required for Task Completion (Mechanical, Electrical, Hydraulic, PLC Programming, Instrumentation, Other)
[ ] Rationale for Task Selection
[ ] Task Priority Level (Critical, High, Medium, Low)

--- MAINTENANCE TASK IMPLEMENTATION & SCHEDULING ---
[ ] Maintenance Task Priority (Based on RCM Analysis) (Critical, High, Medium, Low)
[ ] Scheduled Task Start Date
[ ] Scheduled Task Start Time
[ ] Estimated Task Duration (Hours)
[ ] Detailed Task Instructions & Safety Precautions
[ ] Required Tools & Equipment (Hand Tools, Power Tools, Specialized Equipment, Lifting Devices, Testing Equipment)
[ ] Maintenance Skill Level Required (Level 1 - Basic, Level 2 - Intermediate, Level 3 - Advanced, Level 4 - Expert)
[ ] Attach Relevant Documentation (e.g., diagrams, procedures)

--- RCM DOCUMENTATION & REVIEW ---
[ ] RCM Plan Narrative Summary
[ ] Date of Initial RCM Analysis
[ ] Date of Last RCM Review
[ ] Review Frequency (e.g., every 12 months)
[ ] Review Type (Full Review, Partial Review, Confirmation Review)
[ ] Summary of Review Findings & Actions
[ ] Areas of Review Considered (check all that apply) (Failure Modes, Maintenance Tasks, Task Frequency, Criticality Assessment, Spare Parts Inventory)
[ ] Supporting Documentation (e.g., updated FMEA)
[ ] Reviewer Name
[ ] Reviewer Signature

--- TRAINING AND COMMUNICATION ---
[ ] Training Objectives Description
[ ] Topics Covered in RCM Training (Select All That Apply) (Asset Identification & Scope, Functional Analysis, Failure Mode Identification, Maintenance Task Selection, RCM Logic & Decision Making, Maintenance Procedure Documentation)
[ ] Number of Personnel Trained (Initial)
[ ] Date of Last RCM Training Session
[ ] Summary of Key Training Messages & Communication Strategy
[ ] Communication Method for RCM Updates/Changes (Team Meetings, Email Notifications, Bulletin Boards, Digital Communication Platform (e.g., Slack, Teams))
[ ] Training Materials Upload (e.g., Presentations, Guides)

--- CONTINUOUS IMPROVEMENT & MONITORING ---
[ ] Mean Time Between Failures (MTBF) Trend
[ ] Mean Time To Repair (MTTR) Trend
[ ] Failure Rate (Failures per Unit Time)
[ ] Deviation from Planned Maintenance Task Completion? (On Time, Delayed, Not Completed)
[ ] Observations and Notes on Equipment Performance
[ ] Date of Last RCM Review
[ ] Areas for Potential Improvement Identified? (Task Effectiveness, Task Frequency, Parts Availability, Training Needs, Documentation Accuracy)
[ ] Summary of RCM Plan Effectiveness Discussion

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