RCM Blitz Analysis Estimating Tool – Plan Your Maintenance Investment Wisely

Reliability‑Centred Maintenance (RCM) is a strategic investment that demands careful planning. A well‑executed RCM Blitz analysis not only optimises asset performance but also ensures that the time, resources, and capital you devote yield tangible returns.

Before diving into an RCM session, you must estimate its scope and duration. Four key factors influence this estimate:

1. Component count – the number of distinct elements inside the analysis envelope.
2. Failure‑mode count – the unique ways those components can fail.
3. Information quality – the currency of drawings, OEM data, and historical records.
4. Team experience – the skill level of the RCM team and facilitator.

In practice, a seasoned facilitator can cover 85 to 100 functions and 120 to 140 failure modes in a single week. With experience, these figures can rise by up to 30 %.

To begin, select a critical asset and, using a P&ID drawing, highlight every component within its boundary. A component is a modular part that can be removed or repaired on its own—gearboxes, pumps, limit switches, and the like. Each component represents a single item for counting purposes, regardless of internal parts.

Once you have a complete component list, multiply the count by 1.5 to estimate the number of functions. Aim for 85–100 functions in your initial RCM Blitz. This boundary defines the scope; any components outside it may be addressed in subsequent analyses.

Next, estimate the failure modes for each component using the built‑in Failure‑Mode Estimating Tool. The tool lists common failure modes for each component type, serving as a starting point rather than a definitive template. For example, a motor typically has five frequently observed failure modes:

• Bearings fail due to contamination.
• Bearings fail due to inadequate lubrication.
• Bearings fail due to over‑lubrication.
• Bearings fail due to misalignment with the gearbox.
• Windings fail due to insulation breakdown.

Summing the common failure modes across all components gives you an estimate of total failure modes for the analysis. Keep this number between 120 and 140 for your first Blitz. Remember, these are just guidelines; your actual failure modes should reflect the specific conditions and risks of the asset.

About the author

Douglas Plucknette is the owner and president of Reliability Solutions. With 19 years at Eastman Kodak—including six as a reliability applications engineer and a global RCM trainer/facilitator—Douglas brings deep industry expertise to his consulting and training services in RCM, manufacturing reliability, and failure‑reporting systems.