Reliability Centered Maintenance (RCM) Worksheet
RCM asks what each asset must do, how it can fail and what is the right task to deal with each failure, if any. This worksheet is a practical record of that analysis, with a risk score to help decide where to spend effort first.
| Function | Functional failure | Failure mode | Effect of failure | Severity (1-10) | Occurrence (1-10) | Detection (1-10) | Risk priority (RPN) | Selected task | Task interval (days) (days) | |
|---|---|---|---|---|---|---|---|---|---|---|
96 | ||||||||||
75 | ||||||||||
128 | ||||||||||
72 | ||||||||||
30 |
Add one row per failure mode. After selecting a task, rescore occurrence and detection to confirm the task actually reduces risk. RPN is a ranking aid, not an absolute measure, and many teams also rank by severity first. This worksheet follows the structure of the RCM questions in SAE JA1011 without reproducing the standard.
Use ERP failure history in your RCM
Optional: a short review of how to pull failure and cause history from your ERP into RCM scoring.
Optional. The tool and every export work without this. No spam.
How to use it
Start with one asset or system. Write its function in measurable terms, such as flow, speed or pressure. For each function list the ways it can fail, then the specific failure modes behind each, and the effect on safety, environment, production and cost. Score severity, occurrence and detection from 1 to 10 and the sheet computes the RPN. Then choose a task for each mode and set an interval. Rescore after the planned task to see whether it truly lowers risk, and export the result to Excel.
Task selection logic
RCM does not assume that every failure needs preventive work. Condition monitoring fits failures that give warning before they occur. Scheduled restoration or discard suits wear out failures with a known age pattern. Failure finding checks hidden functions such as standby equipment and protective devices. Run to failure is valid when consequences are minor and repair is cheap. Redesign is for failures that no task can control. These choices follow the general decision logic described in SAE JA1011 and the wider RCM literature.
- Condition monitoring: warning exists and can be detected
- Restoration or discard: clear wear out age
- Failure finding: hidden protective functions
- Run to failure: low consequence, cheap fix
- Redesign: no effective task
Reading the scores
RPN ranks failure modes so you start with the biggest risks. Do not treat the number as exact: a mode with severity 9 deserves attention even if its RPN is modest. In the example, the bearing seizure ranks highest because it trips a furnace, while the idler roller is left to run to failure. Revisit occurrence ratings with real work order history, and use cause codes in your ERP or CMMS to support them.
Common mistakes
Analysing components instead of functions, writing vague failure modes such as pump fails, skipping hidden failures, and assigning time based tasks when failures are random. A full RCM study also needs operators and maintainers in the room. Treat the output as a living record and update it when failures reveal missing modes. The results feed PM schedules, spares decisions and inspection routes.
Frequently Asked Questions
What is the difference between RCM and FMEA?
FMEA lists failure modes, effects and risk. RCM goes further by defining functions and selecting the maintenance task or design change that deals with each failure. This worksheet combines both.
How do I choose the maintenance task for a failure mode?
Ask whether the failure gives warning, whether it is age related and whether it is hidden. Use condition monitoring for detectable warnings, restoration or discard for age related wear, and failure finding for hidden functions.
Is a high RPN always more important than a high severity?
No. RPN multiplies three ratings, so a safety critical mode with high severity and low occurrence can score low. Review severity separately and treat safety and environmental modes first.
How long does an RCM analysis take?
A single system can take from a few hours to several days with a small team, depending on complexity. Start with the most critical assets and use history to speed up the work.
Netray can mine your ERP and CMMS work order history for repeat failure modes and cause codes, so your RCM scoring is based on recorded failures rather than memory.
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