40%
Vessel maintenance overhaul
Maintenance cost reduction across a fleet of 8 offshore support vessels within 24 months, through RCM and spare parts rationalisation.
Read the case study
Maintenance management
FMECA and RCM
Every maintenance task tied to a failure mode. Every other task removed.
Most PM routines are a mix of OEM recommendations, old incident fixes and tasks nobody can explain. A large share prevent nothing, and some cause failures by disturbing equipment that was running fine. We help operators work out how each critical asset actually fails and build the maintenance around those failure modes. Crews get fewer, better tasks, and failures that do happen were expected and planned for.
How we
do it.
Start from the failure, not the task
Reviewing tasks one by one keeps the bad ones in. We list the functions of each critical asset, the ways it can fail and the effect of each failure, drawing on O&M manuals, failure history in your CMMS and the people who maintain it. We pre-fill likely failure modes from manuals and work order history, so workshops start at the review stage, not from a blank sheet.
Strip out tasks with no failure mode behind them
If a task does not prevent, detect or reveal a failure mode, it is cost with no return. We map every existing task to a failure mode and remove or change the ones that do not map. Freed hours go back to work that protects production.
Pick the right strategy for each failure mode
Time-based replacement only works for failures that wear out on a predictable curve. Using Weibull analysis on your failure data where it exists, and OREDA industry data where it doesn't, we choose between condition monitoring, scheduled restoration, failure-finding tests, redesign or run to failure. Each failure mode gets the cheapest strategy that controls the risk.
RCM where it is justified
Full RCM on every asset is slow and expensive. We apply full RCM to C1 assets and a lighter FMECA-based review to C2, so the depth of analysis matches the consequence of failure.
No failure history?
We use OREDA.
Many plants have never recorded enough failures to give a realistic likelihood of failure. Where your own history is thin, we use OREDA, the energy industry's reliability database built from over four decades of offshore and onshore equipment records, to set realistic failure rates. As your own data builds, it takes over.
About OREDAWhat you get.
- FMECA worksheets per asset or asset type
- Task-to-failure-mode map with keep, change and remove decisions
- New PM routines with intervals and justifications
- CMMS-ready task lists
- Summary of hours removed and added
Common
questions.
What is the difference between FMECA and RCM?
FMECA is the analysis: how an asset fails, what happens and how bad it is. RCM is the decision process that uses that analysis to pick a maintenance strategy for each failure mode.
Does every asset need a FMECA?
No. Criticality decides that. C1 assets get the full treatment, low-criticality assets often do not justify it.
How much maintenance does FMECA typically remove?
It varies with how the regime was built.
Can FMECA be done without good failure history?
Yes. Manuals, OEM data and experienced technicians fill the gaps, and the gaps themselves tell you what to start recording.
Related services
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connects.
Talk to an engineer
about FMECA and RCM.
Tell us what you run and what keeps going wrong. We'll tell you straight how we'd approach it.
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