FMECA & RCM Analysis Tool

A comprehensive Streamlit application for conducting Failure Modes, Effects and Criticality Analysis (FMECA) and Reliability Centered Maintenance (RCM) analysis on infrastructure assets.

Overview

This application implements the complete RCM methodology based on the Murrumbidgee Irrigation RCM Course materials, guiding users through:

• Stage 1: Planning & Preparation - Define assets and operating context
• Stage 2: RCM Analysis (FMECA) - Systematic analysis of failures and consequences
• Stage 3: Implementation - Plan maintenance schedules and changes
• Stage 4: Reports & Export - Generate reports and export results

Features

Core RCM Methodology

• 7 RCM Questions Framework: Structured approach answering the fundamental questions of RCM
• FMECA Analysis: Complete failure modes, effects, and criticality analysis
• Consequence Categorization: 6-category system (Hidden/Evident × Safety/Operational/Non-operational)
• Task Selection: Intelligent selection of maintenance strategies (CBM, FTM, FF, Redesign, OTF)

Key Capabilities

• ✅ Asset and component definition with hierarchical structure
• ✅ Operating context documentation
• ✅ Function identification with performance standards
• ✅ Functional failure analysis
• ✅ Failure mode identification at component level
• ✅ Detailed failure effects documentation
• ✅ Risk-based consequence assessment
• ✅ Maintenance task selection and validation
• ✅ Cost estimation and benefit analysis
• ✅ Implementation planning
• ✅ Report generation and data export
• ✅ Import/export for data persistence

Installation

Prerequisites

• Python 3.8 or higher
• pip package manager

Setup

1. Clone or download this repository:

git clone <repository-url>
cd rcm-fmeca-tool

2. Install required packages:

pip install -r requirements.txt

3. Run the application:

streamlit run rcm_fmeca_app.py

4. Open your web browser to the URL shown (typically http://localhost:8501)

Usage Guide

Stage 1: Planning & Preparation

1. Define Your Asset

   • Enter asset name (e.g., "Tharbogang PS2 - Jockey Pump Assembly 1")
   • Select asset class (Pump Station, Water Treatment Plant, etc.)
   • Specify asset type and location
   • Define components (Motor, Pump, VFD, Flow Meter, etc.)

2. Document Operating Context

   • Redundancy configuration (stand-alone, duty/standby)
   • Utilization patterns and loading
   • Quality standards and seasonal demands
   • Skills and spares availability
   • Operating environment and standards

Stage 2: RCM Analysis (FMECA)

Step 2: Identify Functions

Define what the asset is supposed to do:

• Use format: [Verb] + [Object] + [Performance Standard]
• Example: "To pump water from reservoir at 250 L/s at 1,147 kPa"
• Include primary and secondary functions
• Specify quantifiable performance standards where possible

Step 3: Identify Functional Failures

How can the asset fail to meet its functions?

• Complete loss: "Unable to pump any water"
• Partial loss: "Pumps water at less than 250 L/s"
• Exceeds limits: "Pressure exceeds 1,200 kPa"

Step 4: Identify Failure Modes

What specifically causes each functional failure?

• Identify at component level
• Include cause: "Pump bearing seized due to lack of lubrication"
• Categories: Deterioration, lubrication, contamination, disassembly, human error, overloading

Step 5: Identify Failure Effects

What happens when each failure occurs?

• Evidence of failure
• Safety and environmental impacts
• Operational impacts
• Physical damage
• Repair requirements and downtime

Step 6: Categorize Consequences

Determine the significance of each failure:

• Hidden failures: Not evident to operators (protective devices)
• Evident failures: Operators know when it occurs
• Safety/Environmental: Can hurt people or breach environmental standards
• Operational: Affects output, quality, or service
• Non-operational: Only direct repair costs

Step 7: Select Failure Management Tasks

Choose appropriate maintenance strategy:

Proactive Tasks:

• CBM (Condition Based): Monitor condition, intervene when threshold reached
• FTM (Fixed Time): Replace/overhaul at fixed intervals
• FF (Failure Finding): Test hidden failures periodically

Default Actions:

• Redesign: One-off change to equipment/process/procedures
• OTF (Operate to Failure): Accept failure, repair when occurs

Each task must be:

1. Technically feasible (can it be done?)
2. Worth doing (does it address consequences cost-effectively?)

Stage 3: Implementation

Review and plan:

• Maintenance schedules for CBM, FTM, FF tasks
• One-off changes for redesign tasks
• Implementation checklist for tracking
• Resource allocation and scheduling

Stage 4: Reports & Export

Generate comprehensive reports:

• Summary statistics and metrics
• Consequence breakdowns
• Task type analysis
• Detailed FMECA tables
• Export to CSV or JSON
• Import previous analyses

RCM Decision Logic

For Safety/Environmental Consequences:

1. Is a CBM task technically feasible and reduces risk to acceptable level? → Implement CBM
2. If not, is FTM technically feasible and reduces risk to acceptable level? → Implement FTM
3. If not, is FF technically feasible and reduces risk to acceptable level? → Implement FF
4. If not, must Redesign to reduce risk

For Operational/Non-operational Consequences:

1. Is a CBM task technically feasible and cost-effective? → Implement CBM
2. If not, is FTM technically feasible and cost-effective? → Implement FTM
3. If not, is FF technically feasible and cost-effective? → Implement FF
4. If not, evaluate Redesign vs. Operate to Failure based on lifecycle costs

Example: Water Pump Station

Asset Definition

• Asset: Main Pump Assembly 1
• Components: Centrifugal Pump, 250kW Motor, VFD, Flow Meter

Function Example

"To pump water from reservoir to distribution network at 153 L/s at 1,147 kPa"

Functional Failure Examples

1. Unable to pump any water
2. Pumps water at less than 60 L/s
3. Pumps water but pressure below 900 kPa

Failure Mode Example

Component: Pump Bearing Failure Mode: "Bearing seized due to lack of lubrication" Effect: Motor trips, standby pump activates, 2-hour downtime for repair Consequence: Evident (Operational) Task: FTM - Lubricate bearing every 500 hours

Data Persistence

The application automatically saves your analysis in session state. To persist data:

1. Export: Use "Export to JSON" to save complete analysis
2. Import: Upload JSON file to restore previous work
3. CSV Export: Export results table for external analysis

Tips for Effective Analysis

1. Be Specific: Use precise, quantifiable performance standards
2. Focus on Real Failures: Only analyze failure modes that are reasonably likely
3. Document Thoroughly: Complete failure effects enable better decision-making
4. Think Zero-Based: Describe effects assuming no current maintenance (worst case)
5. Validate Tasks: Ensure tasks are both feasible and cost-effective
6. Regular Reviews: Update analysis as conditions change

Technical Details

Application Structure

• rcm_fmeca_app.py: Main Streamlit application
• Session state for data persistence within session
• JSON export/import for long-term storage
• Responsive layout with multi-column design

Data Model

{
  'asset_data': {...},
  'operating_context': {...},
  'functions': [...],
  'functional_failures': [...],
  'failure_modes': [...],
  'analysis_results': [...]
}

Troubleshooting

Issue: Application won't start

• Ensure Python 3.8+ is installed
• Verify all dependencies are installed: pip install -r requirements.txt

Issue: Data lost after closing browser

• Use Export function to save work before closing
• Import JSON file to restore when reopening

Issue: Large analysis is slow

• Consider breaking complex assets into sub-systems
• Use CSV export for large datasets

References

Based on:

• Murrumbidgee Irrigation RCM Course Materials
• RCM II by John Moubray
• ISO 55000 Asset Management Standards
• SAE JA1011 RCM Standard

Support & Contributions

For issues, suggestions, or contributions, please refer to the project repository.

License

[Specify your license here]

Acknowledgments

Developed based on the Murrumbidgee Irrigation FMECA and RCM In-depth Course V1.0 materials.