We have maintenance and operations responsibility for ground test facilities valued at more than $7B at Arnold Engineering Development Center (AEDC). Costs to achieve required reliability and availability of the aging infrastructure were much higher than desired, and the proactive maintenance ratio was low (less than 50%) meaning most maintenance actions were reactive in response to failures. We recognized that a proactive approach to maintenance, and the associated potential improvements in systems’ overall reliability and availability, could have a significant impact on AEDC’s fiscal bottom line. As such, we initiated a comprehensive maintenance improvement program based on Reliability Centered Maintenance (RCM) approaches.

Our Approach/Solution – We began with an extensive review of various RCM analysis approaches, and then conducted multiple RCM pilot projects using models ranging from the rigorous classical approach to much simpler and less time-consuming techniques. Based on these pilot results, we selected and adapted the “best-fit” model for AEDC facilities and equipment. We then trained multi-disciplined teams composed of craft and engineering personnel to perform the analyses and implement recommendations.

To date, we have performed 29 analyses impacting 53 major systems. We have also implemented over 2,000 specific recommendations drawn from our analyses, and have received funding approval for 100 other recommendations as part of AEDC’s investment program.

Results and Benefits – Our RCM-based maintenance management program has been a major factor in reducing AEDC’s plant downtime from 12% to less than 5%. The proactive maintenance ratio has increased from less than 50% to greater than 65%, which is comparable to best-in-class for facilities similar to AEDC. Equipment availability has increased from 91% to 95%. The preventive maintenance backlog has been reduced by a factor of 7 (from 1,100 past due PMs to less than 160). We have result of the maintenance improvements, we have reduced the overall costs of performing work at AEDC – including a 25% decrease in our operations and maintenance staffing.

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