Application of Reliability Centered Maintenance (RCM) at the Bi-State Development Agency
In 2002 the executive staff at Metro St. Louis decided that a change in direction for vehicle maintenance was necessary. After years of poor service quality, excessive
vehicle breakdowns and inconsistent budgeting the Vehicle Maintenance Department was mandated to developed a maintenance program that controlled costs, improve vehicle performance and extend the life of a bus to 15 years.
Delays to service averaged 3,500 miles
Maintenance management was focused on managing breakdowns not managing equipment
Maintenance philosophy was more inspections would produce better results
Components, parts and systems were operated to failure
Restoration and discard activities were performed at asset end life to meet service needs
Budgeting was not consistent year to year
No comprehensive capital replacement plan for vehicles
Asset Manager's solutions and added value
Developed maintenance program using Reliability Centred Maintenance (RCM) principals and guidelines for all vehicles that addressed executive staff concerns.
Developed whole life cost models for all vehicle components, parts and systems that extends the life of the assets
Plan expenditures at the mid-life of the asset life cycle including scheduled restoration and scheduled discard activities in order to maximize ROI
Extend the life of a bus by 20% from 12 years to 15 years increasing asset availability
Grouped maintenance activities in order to maximize maintenance department's productivity
Developed Bill of Materials (BOM) for scheduled maintenance activities
Created a training program that supports the RCM philosophy for all vehicle maintenance employees
Reduced unnecessary work activities 66%
Developed 25 years capital replacement plan for all rolling stock
Key benefits and success factors
Key benefits and success factors.
Vehicle reliability increased to over 20,000 miles between delays to service.
Improved customer experience, reduced customer complaints by over 90% through better manpower utilization and scheduled restoration activities.
Decreased vehicle operating cost per mile 50% Reduced inventory for vehicle maintenance by 66%.
The RCM program resulted in reliable and consistent zero based budgeting.