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NAVAIR 00-25-40301 July 2005MANAGEMENT MANUALGUIDELINES FOR THE NAVAL AVIATIONRELIABILITY-CENTERED MAINTENANCEPROCESSThis manual supersedes NAVAIR 00-25-403 dated 01 March 2003.DISTRIBUTION STATEMENT A. - Approved for public release; distribution isunlimited.PUBLISHED BY DIRECTION OFCOMMANDER, NAVAL AIR SYSTEMS COMMAND0800LP1046697NATEC ELECTRONIC MANUAL
NAVAIR 00–25–4032 July 2005NAVAIR 00–25–403, DATED 1 July 2005, CONTAINS A FEW INCORRECT PAGES. REMOVE AND DISCARD PREVIOUSLY PROVIDED PAGES AND REPLACE WITH ATTACHED PAGES.PLACE THIS NOTICE SHEET BEHIND MANUAL TITLE PAGE AFTERCOMPLETING REQUIRED ACTION.
NAVAIR 00-25-40301 July 2005LIST OF EFFECTIVE PAGESDates of issue for original and changed pages are indicated below:Original 0 .01 July 2005Insert latest changed pages. Dispose of superseded pages in accordance with applicableregulations.NOTE: A vertical line or other change symbol in the outer margin of the page indicates theportion of the text affected by the latest change. Changes to illustrations are indicated byminiature pointing hands.Total number of pages in this manual is 194 consisting of the following:PAGE NO.#CHGNOPAGE NO#CHGNOPAGE NO#CHGNOTitle 04-12 Blank .0A-37 – A71 .0A . 05-1 – 5-11 0A-72 Blank .0i –v . 05-12 Blank . .0A-73 – A77 .01-1 – 1-5 0A-1 – A-30 .0A-78 Blank .01-6 Blank 0A-31 Blank .0A-79 02-1 – 2-24 .0A-32 – A-33 0A-80 Blank .03-1 – 3-39 .0A-34 Blank. 0A-81 – A82 .03-40 Blank . 0A-35 . .0B-1 – B-8 . 04-1 – 4-11 .0A-36 Blank .0*Zero (0) in this column indicates an original pageA
NAVAIR 00-25-403TABLE OF CONTENTSLIST OF EFFECTIVE PAGES. ATABLE OF CONTENTS .iIINTRODUCTION . 1-11.11.21.31.41.5IIPURPOSE . 1-1SCOPE . 1-1DEFINITIONS. 1-2ACRONYMS. 1-3REFERENCE DOCUMENTS. 1-5RCM PROGRAM MANAGEMENT . 2-12.1INTRODUCTION . 2-12.2RCM DURING ACQUISITION PHASES . 2-22.2.1 Prior to Milestone A (Concept & Technology Development). 2-32.2.2 Prior to Milestone B (System Development and Demonstration) . 2-42.2.3 Prior to Milestone C (Production & Deployment). 2-42.2.4 During Full Rate Production and subsequent (Operations & Support) . 2-62.3RCM TEAM ESTABLISHMENT (Management, Analysis, Sustainment) . 2-72.3.1 RCM Team Composition. 2-72.3.1.1 Program Management. 2-72.3.1.2 Fleet Support Team. 2-82.3.1.3 Competencies. 2-82.3.1.4 Original Equipment Manufacturer (OEM) or Supporting Contractors. 2-82.3.1.5 Equipment Controlling Custodians, Operators, & Maintainers. 2-82.3.2 Ancillary Support Requirements. 2-92.3.3 Knowledge and Skills Requirements . 2-92.3.4 Contracting For RCM . 2-92.3.5 Conducting The Analysis. 2-102.4SCOPE OF ANALYSIS . 2-102.4.1 Determining Scope of Analysis . 2-112.4.2 Hardware Partitioning. 2-112.4.3 Level of Analysis . 2-122.4.4 Hardware Selection. 2-13i
NAVAIR 00-25-4032.4.5 Extent of Analysis. 2-142.5GROUND RULES AND ASSUMPTIONS . 2-152.5.1 General Considerations. 2-152.5.2 Failure Modes, Effects, and Criticality Analysis (FMECA). 2-162.5.3 Task Analysis. 2-172.6TRAINING AND CERTIFICATION . 2-172.6.1 NAVAIR RCM Training Courses . 2-182.6.1.1RCM Management Overview, Orientation, and Fundamentals Courses. 2-182.6.1.2Propulsion and Power Course Offering . 2-182.6.2 Data Analysis Training . 2-182.6.3 Other Training Topics. 2-192.6.4 Certification . 2-192.6.4.1 Level 1 . 2-192.6.4.2 Level 2 . 2-202.6.4.3 Level 3 . 2-202.6.4.4 RCM Site Coordinator . 2-212.6.4.5 RCM Trainer. 2-212.7RCM PROGRAM REPORTING . 2-212.8FUNDING REQUIREMENTS. 2-222.9DATA SOURCES . 2-222.10 RCM PROGRAM METRICS . 2-232.11 IMPLEMENTATION OF RESULTS . 2-232.12 RCM PROGRAM SUSTAINMENT EFFORTS . 2-24IIIRCM ANALYSIS PROCESS . 3-13.1INTRODUCTION . 3-13.2FAILURE MODE EFFECTS AND CRITICALITY ANALYSIS. 3-23.2.1 Function . 3-23.2.2 Functional Failure. 3-43.2.3 Compensating Provisions . 3-43.2.4 Failure Mode. 3-53.2.5 Failure Effect . 3-63.2.6 Failure Detection . 3-73.2.7 Severity Classifications . 3-83.2.8 Mean Time Between Failure (MTBF). 3-83.3SIGNIFICANTFUNCTIONIDENTIFICATION.3-103.3.1 Significant Function (SF) Logic . 3-103.3.2 SF Logic Questions. 3-11ii
NAVAIR 00-25-4033.4RCM DECISION LOGIC. 3-123.4.1 Failure Consequences . 3-133.4.2 Decision Logic Branches. 3-153.5TASK EVALUATION . 3-153.5.1 Servicing Task . 3-153.5.2 Lubrication Task. 3-163.5.3 Corrosion Preventive Compounds. 3-163.5.4 Servicing/Lubrication Task Cost Analysis . 3-163.5.5 On Condition Task. 3-173.5.5.1 On Condition Task Development . 3-173.5.5.2 Identifying the Functional Failure Condition . 3-183.5.5.3 Identifying the Potential Failure Condition . 3-183.5.5.4 Determining the PF Interval. 3-193.5.5.5 On Condition Task Interval Development. 3-193.5.5.6 On Condition Task Cost Analysis. 3-213.5.6 Hard Time Task . 3-213.5.6.1 Hard Time Task Development. 3-213.5.6.2 Wear Out. 3-223.5.6.3 Survival to Wear Out Age. 3-223.5.6.4 Hard Time Task Interval Development . 3-233.5.6.5 Hard Time Task Cost Analysis . 3-243.5.7 Failure Finding Task. 3-243.5.7.1 Failure Finding Task Interval Development . 3-243.5.7.2 Hidden Economic/Operational Failure Modes . 3-243.5.7.3 Failure Finding Task Cost Analysis. 3-243.5.8 No PM. 3-253.5.8.1 “No PM” Cost Analysis . 3-253.5.9 Other Action Warranted . 3-253.5.9.1 “Other Action Warranted” Cost Analysis. 3-263.5.10 Age Exploration (AE). 3-263.5.10.1 AE Task Development. 3-273.5.10.2 AE Tasks for Failure Modes with Safety/Environmental Consequences. 3-273.5.10.3 AE Tasks for Failure Modes with Economic/Operational Consequences. 3-283.5.10.4 AE Sample Quantity . 3-283.5.10.5 AE Task Selection. 3-283.6RCM TASK SELECTION . 3-293.6.1 Basis for Decisions . 3-29iii
NAVAIR 00-25-4033.6.1.1 Cost . 3-293.6.1.2 Operational Consequences. 3-293.6.1.3 Cost Equation Limitations . 3-333.7SPECIAL CONSIDERATIONS. 3-343.7.1 Prognostics and Health Management (PHM) Systems. 3-343.7.2 Combination of Tasks. 3-373.7.3 Zonal Inspections and Walkaround Checks . 3-373.7.4 Event-Driven Tasks . 3-373.7.5 RCM Audits and Assessments. 3-38IVIMPLEMENTATION OF RCM ANALYSIS RESULTS. 4-14.1INTRODUCTION . 4-14.2PACKAGING PM TASKS. 4-24.2.1 Initial Packaging Strategy. 4-24.2.1.1 Step 1 - Lay Out Tasks by Interval and Preliminary Maintenance Level. 4-24.2.1.2 Step 2 - Identify Logical Task Groupings. 4-44.2.1.3 Step 3 – Develop Final Packaging . 4-44.2.2 Fitting Tasks Into Existing Packages. 4-64.2.3 Repackaging . 4-64.2.4 Special Considerations for PHM Driven Tasks . 4-64.2.5 Environmental Considerations. 4-74.3IMPLEMENTATION OF OTHER ACTIONS . 4-84.3.1 Mandatory Action. 4-84.3.2 Desirable Action . 4-94.4IMPLEMENTATION OF AE TASKS. 4-94.5PERFORMING PM TASKS EARLY . 4-10VSUSTAINMENT OF RCM PROGRAM. 5-15.1INTRODUCTION . 5-15.2SUSTAINING THE ANALYSIS . 5-25.2.1 Top Degrader Analysis . 5-25.2.2 Trend Analysis. 5-45.2.3 PM Requirements Document Reviews. 5-45.2.4 Task Packaging Reviews . 5-55.2.5 Fleet Leader Programs. 5-55.2.6 Age Exploration Tasks . 5-65.2.7 Emergent Issues . 5-65.2.7.1 Problem Assessment . 5-7iv
NAVAIR M Corrective Action. 5-7Interim Action. 5-7RCM Review. 5-7RCM Update . 5-7Sources of Emergent Issues. 5-75.3 RESULTS OF SUSTAINING EFFORTS . 5-85.4 ASSESSMENT OF RCM PROGRAM EFFECTIVENESS. 5-95.4.15.4.25.4.35.4.4Cost avoidance . 5-9Maintenance Performed. 5-10Operational Readiness . 5-11Other Parameters . 5-11APPENDIX APART 1 – RCM PROGRAM PLAN1INTRODUCTION . A-62BACKGROUND . A-33SCOPE . A-64SUSTAINING THE PROGRAM. A-64.1 GENERAL .A-64.2 DATABASE MANAGEMENT.A-74.2.1Depot Failure Database .A-74.2.2RCM Analysis Databases .A-74.2.3RCM History Log .A-74.2.4Maintenance Specification Management .A-74.3 GROUND RULES AND ASSUMPTIONS .A-74.3.1Aircraft Data.A-84.3.2Acceptable Probability of Failure .A-84.3.3Labor Rates .A-94.3.4System Boundaries and Interface Items .A-94.3.5Performance Parameters.A-94.3.6Analytical Methods.A-104.3.7Mandated Tasks .A-104.4 RCM PROCESS FLOW .A-104.4.1Analysis Method .A-134.4.2Data Collection .A-13v
NAVAIR 00-25-4034.4.3Data Sorting (Potential or Functional). A-144.4.4Failure Modes (FMs) . A-154.4.5Potential Failure to Functional Failure (PF) Interval Determination . A-154.4.6Wear Out Characteristic Determination . A-154.4.7Categorization of Failure in Accordance with Risk Assessment Matrix . A-164.4.8Integrated Reliability-Centered Maintenance System (IRCMS) . A-184.4.9Task Interval Calculation . A-184.4.10 Collection of Cost Data: . A-224.4.11 RCM Process Outcomes . A-224.4.12 Age Exploration (AE) . A-234.4.13 Packaging. A-234.5TASK REVIEW AND APPROVAL . A-234.5.1Analyst. A-234.5.2Fleet Review and Input . A-244.5.3Evaluator and Estimator (E & E) Input. A-244.5.4Manufacturer’s Input. A-244.5.5RCM Team Leader Review . A-244.5.6Lead Logistician Review . A-244.5.7Lead Engineer Review . A-254.5.8RCM Team Leader Final Approval . A-254.6TASK IMPLEMENTATION . A-254.6.1Implementing a Depot Level Change . A-254.6.2Implementation of Organizational or Intermediate Level Changes . A-254.6.3Work Unit Code (WUC) Manual Updates . A-254.7PERFORMANCE MONITORING . A-254.7.1Monitoring Methodology . A-264.7.2Recognition of Undesirable Trends . A-264.8REVIEW FREQUENCY. A-274.9DOCUMENTATION AND REPORTING REQUIREMENTS . .A-274.10WORK PRIORITIZATION. A-275 RCM TRAINING. . A-275.1RCM ANALYSTS AND RCM TEAM LEADERS . . A-275.2FLEET SUPPORT TEAM LEADERS . .A-286 TEAM STRUCTURE. A-287 FUNDING REQUIREMENTS. A-30vi
NAVAIR 00-25-403APPENDIX APART 2 – PROPULSION AND POWER SYSTEM RELIABILITY CENTEREDMAINTENANCE PROGRAM PLAN1.0INTRODUCTION . A-391.1 PURPOSE .A-391.2 SCOPE. .A-391.3 BACKGROUND .A-391.4 REFERENCED DOCUMENTS .A-401.5 CHANGE RECOMMENDATIONS .A-421.6 LIST OF ACRONYMS. A-422.0RESPONSIBILITIES . A-472.2 [FST ID] FLEET SUPPORT TEAM (FST) [LOCATION].A-472.3 NAVAL AIR SYSTEMS COMMAND (NAVAIR) .A-492.4 VENDOR (OEM) OR CONTRACTOR SUPPORT SERVICES (CSS) .A-503.0SCOPE OF ANALYSIS. A-513.1 INITIAL ANALYSIS GUIDELINES AND STEPS .A-513.2 SUSTAINING ANALYSIS GUIDELINES AND TASKS . A-554.0RCM ANALYSIS GROUND RULES AND ASSUMPTIONS . A-574.1 ANALYSIS COVERAGE .A-574.2 METHODS FOR PRIORITIZING FAILURE MODES FOR ANALYSIS .A-584.3 ANALYSIS ASSUMPTIONS .A-604.4 RCM PROGRAM METRICS .A-624.5 SINGLE INSPECTION EFFECTIVENESS .A-634.6 MINIMUM DETECTABLE FLAW SIZES .A-634.7 FAILURE MODE EFFECTS AND CRITICALITY ANALYSIS .A-634.8 TASK ANALYSIS.A-654.9 SUSTAINING TASK PRIORITIES . A-654.10 DESIGN CHANGES .A-665.0DOCUMENTATION REQUIREMENTS . A-665.2 INTEGRATED RELIABILITY CENTERED MAINTENANCESOFTWARE (IRCMS) . A-665.3 AE DATABASE.A-675.4 RCM AUDIT LOG .A-675.5 QUARTERLY RCM REPORTS .A-68vii
NAVAIR 00-25-4036.0RCM PROGRAM EVALUATION . A-687.0TRAINING REQUIREMENTS . A-698.0MILESTONE CHART . A-699.0FUNDING REQUIREMENTS . A-69Attachment (1) [ACFT ID] Propulsion and Power SystemsAttachment (2) RCM Based Maintenance ProcessAttachment (3) Detailed Information for Calculating [ACFT ID] PPS MetricsAttachment (4) [ACFT ID] PPS Major Intermediate And Depot Preventive Task IntervalHistory And RCM GoalsAttachment (5) Example of Quarterly ReportAttachment (6) [ACFT ID] PPS RCM POA&MAPPENDIX B1INTRODUCTION . B-21.2ON CONDITION TASK INTERVAL DETERMINATION . B-21.2.1Using Acceptable Probability of Failure and Task Effectiveness .B-21.2.2Optimizing Task Intervals for Failure Modes with Non-SafetyConsequences.B-41.2.3Methods for Estimating Potential-to-Functional (PF) Interval.B-51.3HARD TIME TASK INTERVAL DETERMINATION. B-71.3.1Weibull analysis .B-71.3.2Testing .B-71.3.3Fatigue
RELIABILITY-CENTERED MAINTENANCE PROCESS This manual supersedes NAVAIR 00-25-403 dated 01 March 2003. DISTRIBUTION STATEMENT A. - Approved for public release; distribution is unlimited. PUBLISHED BY DIRECTION OFCOMMANDER, NAVAL
