Frequently Asked Questions
RCM3 is now the new standard for how organizations manage their operational risks and improve asset integrity.
- RCM3 exceeds SAE standards and broadens RCM2 capability to align with more recent and international accepted ISO Management Systems (ISO 55001 and ISO 31000).
- RCM3 is fully integrated with other Business Risk Management Systems like Root Cause Failure Analysis, Risk Centered Spares (RCS) and HAZOP.
- RCM3 is no longer just another initiative, but a mainstream business risk management process that could become the most important management system for improving Process Safety and Asset Integrity.
- Our new risk-based methodology is the only process companies need to maintain and optimize all their assets (rotating and static).
- RCM3 is the best response to the challenges and expectations brought by the Fourth Generation Maintenance.
- RCM3 is now the process industry’s most advanced method for managing maintenance and operations to control costs and boost overall productivity.
Compare RCM2 to RCM3 with this progression table that illustrates the extended capabilities of RCM3. Click to view it here.
Most consulting firms will recommend starting with a gap analysis to understand what processes and/or systems you already have in place that will lend themselves to a successful RCM journey. This “gap assessment” can be done internally with a basic understanding of the RCM steps.
At Aladon, we recommend starting by reviewing the RCM process at the executive level. Reviewing and understanding the 7 questions of RCM and the 14 maxims of RCM will provide a basic understanding to build upon and assist with the gap assessment. Other reference material that should be reviewed and understood are:
- SAE JA 1011
- ISO 55000 International Standard for Asset Management
- ISO 31000 Risk Management
Aladon’s systematic approach to certifying an RCM Facilitator takes place in three stages. The first stage consists of attending an introductory course in order to provide the necessary background and context to participate in an RCM analysis. During the introductory course delegates are taught how to apply best practices using a case study approach that prepares them to develop the competency of a facilitator in the skills necessary to produce safe, defensible analyses.
Aladon’s REW Software was designed to seamlessly integrate with our thoughtware. We used the experience we gained in the application of our award-winning thoughtware to develop world-class integrated software, designed to support the work of a reliability professional.
By combining our thoughtware with our software, you can access the best information for tactical and strategic decisions to proactively manage your business reliably and safely.
Aladon’s software solution is designed to develop asset care strategies that create a culture of reliability in your organization, and it is only by using the software to support the thoughtware that you can maximize your asset management care. This requires extensive training in Aladon thoughtware, such as ACAP, RCFA, RCM2™/RCM3™, MTA, CA and RCS or support from an Aladon Network Member.
Our goal is for you to get the most efficient and effective use of your physical assets and resources.
Aladon offers a systematic approach to our proven RCM methodologies, RCM2™/RCM3™ within organizations. We offer a step-by-step process, with a go/no go decision point after each step. That means you determine as you go along if the Aladon RCM™ methodology is right for you.
- Executive overview: We start with a one day overview of RCM2/RCM3 processes and methodologies to your organization’s stakeholders, including: union leaders, sponsors of the program and anyone on the team who has oversight of the maintenance. This leadership team can then decide if they want to proceed with Aladon training.
- Introductory training: We begin training with a 3-day introductory RCM2/RCM3 course with engineers, operators, maintenance team members, union leaders and subject matter experts. Following the completion of this introductory course, the team decides if they should proceed with continuing education.
- Advanced classroom training: The next step is a more intense 10-day training with select members of the group who joined the introductory course. These select members will learn to become a group facilitator and will join follow up mentoring.
- Mentoring: We next take a select group through a pilot project where they analyze equipment that they have. This is a three-week process that occurs on site.
- Execution: The facilitators will execute the new maintenance program with support from Aladon. We provide ongoing training and mentoring to ensure your organization applies the RCM process directly and assets are performing at the right level. As part of this process, your organization becomes a site where you continue to implement our methodologies and can purchase our REW software.
To become a network member, your organization must have an Aladon certified practitioner in your organization. For more information, contact Aladon.
As an Aladon certified practitioner, you will be joining a prestigious network of experts well regarded in every industry. You’ll be able to deliver courses, coach facilitators and deliver the Aladon strategy worldwide.
The practitioner course is comprised of three intensive weeks where the participant develops an in depth understanding of the Aladon RCM and the Aladon Strategy. To qualify participants must comply with the criteria as set forth by Aladon. Participants learn how to teach the methodologies and learn how to coach facilitators. To be successful the participant will demonstrate strong leadership and facilitation skills, a good grasp of change management and coaching techniques and mastery of the subject. The days are typically 10 to 12 hours long, concluding with a five-hour exam on the last day (Saturday). Following the three-week classroom training, candidates will be required to deliver a three-Day RCM Introductory Course under supervision of an experienced certified “Aladon Practitioner.”
Our software is flexible and easy to integrate with Work Management Systems. For more information please contact us.
Our advanced software is an integral part of our reliability and asset management thoughtware. Integrating software with each thoughtware without sacrificing its integrity requires a complete understanding of the thoughtware as well as the skills to transfer the thoughtware to a software support tool. Our software knowledge is based on decades of providing asset management services in the military and commercial industries.
- Captures the asset information in hierarchical form (ISO 14224)
- Provides an evaluation (snapshot) of the condition of your organization’s assets for assisting with long term planning and strategy review using the Aladon’s Condition Assessment (ACES)
- Allows you to develop an understanding of which assets impact the business most using Aladon’s Asset Criticality and Prioritization (ACAP)
- Develops maintenance and asset care strategies based on criticality and priority using the Aladon trademark methodologies (RCM2, RCM3, MTA, and more.)
- Develops risk mitigation strategies and defect elimination where failures happen using the Aladon Root Cause Failure Analysis method (RCFA)
- Reduces risk, increases reliability and availability and produces the most cost effective and safe maintenance solutions (integration of methodologies)
- Identifies critical spare parts and records the spare parts at asset level using the Aladon Risk-centered Spares methodology (RCS)
- Develops asset performance indicators for information such as lab test results, equipment sensors, condition assessments, inspections (performance, temperature, vibration, oil level, etc.)
- Develops asset operating and performance scenarios and simulates reliability and availability outcomes using Reliability Centered Design (RCD), Monte Carlo and Weibull analysis
- Tracks asset performance initiatives for risk mitigation and cost reduction
- Imports maintenance information such as PMs and job plans from work management systems (e.g. SAP and Maximo) for reliability reviews
- Uses asset work order history with Weibull analysis to estimate remaining life and to optimize PM intervals
Even if your organization has an asset maintenance program to help increase productivity and optimize your assets, a shortage of expertise in the area of asset failure could send your critical risks spiraling out of control.
With Aladon’s expertise in FMECA, we can help you identify potential failure modes for a product or process, assess the risk associated with those failure modes, and carry out corrective measures to address the most critical issues.
The FMECA methodology is an effective tool for improving designs for products and processes—resulting not only in higher reliability and better quality, but also increased safety, enhanced customer satisfaction and reduced costs.
FMECAs can also be used to establish the need for maintenance programs (for maintainable items) and contribute to quality assurance procedures. It provides a knowledge base of failure modes (causes and mechanisms) and associated corrective action information that is useful for future training, troubleshooting, root cause failure analysis, and RCM based maintenance programs.
The P-F Curve is a term pioneered and used for the first time by John Moubray, the founder of Aladon. The P-F Curve defines and illustrates the interval between a potential failure (when the failure can be detected for the first time) and the functional failure of a physical asset.
The P-F Curve represents very specific failure characteristics and defines the interval between the potential failure “P”, and the functional failure “F”. The P-F Curve is only valid for assets or components that behave technically in a way where the onset of failure is a random event and following the event provides the user with a detectable warning that the functional failure is in the process of happening or about to happen. The functional failure does not necessarily mean complete failure and is based on performance standards as defined by the user.
Any equipment over time and through use will fail, as any plant or physical asset owner knows. The good news, though, is that it can take a long time between when a physical asset potentially fails and reaches the point of actual failure. The key is to fix or replace the asset or equipment before the point of failure.
The true meaning of the P-F Curve is the period between P and F, the Potential Failure (Detectable State) and the Functional Failure (Failed State). The P-F Interval is used to determine the task interval or frequency of predictive or condition-based maintenance (CBM).
A successful reliability program requires a top to bottom culture of reliability. Aladon’s systematic approach is based on training – changing the way people think – and implementation – changing the way people work.
The biggest challenge to reliability maintenance is that this obviously takes time. There may be small payoffs in the beginning of the process, but the full reward of a reliable system of proactive risk management can (and often does) take years, although the benefits start to flow almost immediately. In the end, a proactive approach to maintenance pays off with sustainable results.
An RCM3™ process can take 2-5 years, depending on your organization’s size and industry. In the end, the Aladon approach will change the way your organization thinks about maintenance while providing operations and maintenance workers with a common language and a set of values. Throughout the process, we offer formal training, assisted implementation and support so that your organization has peace of mind and success.
We receive requests for remote training regularly, however since COVID-19, the number of requests is obviously increasing. After multiple requests from Network members to deliver online training, as well as requests from potential clients inquiring about remote training, we investigated ways to possibly deliver the 3-day RCM Introductory course and 2-day RCFA Introductory courses online.
We delivered training sessions internally to our own staff and evaluated multiple platforms and techniques. After performing the training, we realized there were many challenges for efficiently and effectively delivering training which did not meet Aladon’s quality that we are known for.