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Use with Quick Start Repository: Revision 2.0

Quick Start Guide

Version 8

Version 8



Xfmea/RCM++ 8 Quick Start Guide

Part Identification: RPQSXR8

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express written permission of ReliaSoft Corporation, Tucson, AZ, USA.

Disclaimer

Information in this document is subject to change without notice and does not represent acommitment on the part of ReliaSoft Corporation.

Companies, names and data used herein are fictitious unless otherwise noted.

Use of the software and this document are subject to the terms and conditions set forth inthe accompanying license agreement.

This software and documentation were developed at private expense; no portion wasdeveloped with government funds.

TrademarksReliaSoft, Xfmea, RCM++, Synthesis Platform, Synthesis Elements, Weibull++, ALTA and

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Other product names and services identified in this document are trademarks of their

respective trademark holders, and are used for illustration purposes. Their use in no way

conveys endorsement or other affiliation with ReliaSoft Corporation.

10 9 8 7 6 5 4 3 2



Xfmea/RCM++ Quick Start Guide 1

Thank you for your interest in ReliaSoft's Xfmea and RCM++ software tools. This quick start guide has

been designed to help you explore many of the software's key features by working through step-by-step

instructions for some practical application examples.

In order to demonstrate a variety of different applications for the tools available in Xfmea and RCM++,

this guide asks you to imagine that you are the leader of a team of engineers working through the Designfor Reliability (DFR) and maintenance planning activities for a new single light pendant chandelier.

Please note that the sample analyses provided are fictional and intended for demonstration purposes. They

are not intended to be realistic. Furthermore, note that although this guide attempts to introduce you to

some of the most frequently used tools, Xfmea and RCM++ support many other methods and

applications. Within the software, you can choose File > Help to access a wide array of resources that will

help you explore other capabilities.

In addition to this introduction, the following chapters are presented in this guide. Note that the examplesin chapters 3 through 6 can be performed in either Xfmea or RCM++. RCM++ is required for the

examples in chapters 7 and 8.

Chapter 2: Working in Xfmea/RCM++ ............................................................................................... page 3

Chapter 3: Using the DFR Planner ......................................................................................................page 9

Chapter 4: System Hierarchy and Risk Discovery.............................................................................page 17

Chapter 5: Performing Design FMEAs..............................................................................................page 25

Chapter 6: Failure Modes and Reliability Analysis (FMRA)............................................................page 43

Chapter 7: FMRA - Availability and Maintenance Cost Estimation .................................................page 55

Chapter 8: Traditional RCM Analysis for a Conveyor Belt ..............................................................page 71

Xfmea/RCM++ 8

Quick Start Guide 1



1 Xfmea/RCM++ 8 Quick Start Guide

2 Xfmea/RCM++ Quick Start Guide

The quick start repository that is included with the software, (called “xfmea_rcm8_quickstart.rsrp”)

contains sample projects that show the examples in this guide at various stages of completion. To accessthis file, choose File > Help, click Open Examples Folder, then browse for the file in the Xfmea or

RCM sub-folder.

When applicable, the instructions in this guide will refer to a completed project in the quick start

repository. While reading any example in this guide, you have the choice to:

Examine how it was completed in the sample project.

Copy data/analyses from the sample project to help you perform the steps on your own.

Tip: To preserve the integrity of the shipped example files, the software creates a copy of the file each time you

access a repository in the Examples folder. The copy has the same name as the original file and is saved in the

default documents folder for your computer (e.g., My Documents\ReliaSoft\Files). Use the copy to work on the

example projects and save your changes. Any changes you make in the copy will not affect the original file.

IMPORTANT: Note that it may sometimes be necessary to modify the data in the quick start repository to fit

updated instructions or new examples in the latest printing of this quick start guide. This printing of the guide

was designed for use with Revision 2.0 of the Xfmea/RCM++ quick start repository (i.e.,

“xfmea_rcm8_quickstart_rev2.rsrp”). If the example files installed on your computer do not include this revision

of the repository, the information displayed in the sample projects may not match the instructions printed here.

From within the software, you can choose File > Help > Quick Start Guide to download the latest printing.




This chapter provides some general information about the Xfmea/RCM++

interface that may be helpful to understand before you start working through

the examples that begin on page 9. Specifically, this chapter introduces the

way you can use predefined profiles to configure a project to fit your

organization's needs for a specific type of analysis (e.g., different settings

for design FMEAs vs. process FMEAs vs. RCMs). It also discusses how youcan use the flexible system hierarchy interface to manage different types of

analyses for any item in even the most complex system configuration.

Finally, it explains how you can switch back and forth between three different views of the FMEA data in

order to choose the display that is best suited for the specific tasks that you're currently performing.

The step-by-step instructions in the chapters that follow will assume that you're generally familiar with

these three major aspects of the software interface.

Extensive Customization Options to Fit Your Particular Process

There are many flexible capabilities to customize Xfmea/RCM++’s interface and reports to meet the

specific needs of your organization. Some of the configuration options include the ability to:

Define the data fields you want to capture and display.

Set the classifications, categories and other drop-down lists throughout the software.

Determine the rating scales and other criteria that will be used for RPNs or criticality analysis.

Define the logic that will be used for risk discovery analysis.

In RCM++, define the logic that will be used for equipment selection, failure effect categorization

and maintenance task selection.

Working in Xfmea/RCM++ 2

Customization

System hierarchy

FMEA views

Watch a video of this example at

http://www.ReliaSoft.tv/xfmea/startguide/xfmea_qsg_2.html.

http://www.reliasoft.tv/xfmea/startguide/xfmea_qsg_2.html




2 Working in Xfmea/RCM++


The Profiles/Libraries Manager allows authorized users to manage predefined sets of configurable settings

in a library. This library will contain one or more profiles that can be used to set all of the configurable

settings for a particular type of project. For example, you might have one profile for design FMEAs and

another profile for process FMEAs; or for RCM++ users, another profile for RCMs.

The simplest way to set the properties for a particular project is to choose a profile from a drop-down list

on the General tab of the Project Properties window. It is important to note that the settings are copied

from the active library to each project, not linked. If you change a predefined profile in the active library,

the settings for existing projects will not be updated automatically. However, you can easily apply the

latest settings to an existing project by opening the Project Properties window and choosing the profileagain from the drop-down list.

You also have the option to edit configurable settings directly from within the project. If you edit the

individual project’s settings on the Configurable Settings tab of the Project Properties window, the

changes affect the current project only and do not automatically update the profile. If you want to use the

current settings from a particular project to create a new profile in the active library, click the Send





Settings to Library button. The following graphic demonstrates the ways that settings can be transferred

between the active library and any individual project.

Perform Analyses for Any Item in a Large Multi‐Level System Configuration

The software's flexible system hierarchy interface allows you to manage large, multi-level system

configurations with as many levels as you need, and any number of items per level. You can fully define

Note: In

this

guide,

the

examples

use

predefined

profiles

that

are

shipped

with

the

software.

For

your

ownimplementation, it is likely that you (or someone else in your organization) will determine which profiles meet the

specific needs of your organization and configure the active library so these “approved” settings are the only

options available when users create new analysis projects.





the properties for each item (e.g., supplier, part number, expected operating environment, etc.) and

perform FMEAs and related analyses at any level within the system configuration (e.g., system, assembly

and/or component).

To choose which analysis columns will be displayed on the System Hierarchy tab of the System panel,right-click a column header in the system hierarchy, then click Customize Columns. These columns

allow you to see at-a-glance which analyses are present for each item.

For example, examine the following picture. You can see that the chandelier item has a DFR planner

analysis defined, as shown by the icon. Four items have a risk discovery analysis, as shown by the

icons. These four items also have FMEAs, as shown by the icons.

The preferences for which columns will be displayed in the system hierarchy table (or any other similar

table) are stored per computer/username on the System Hierarchy page of the Application Setup (File >

Application Setup), so any project that you open on this computer will have the same columns displayed.

Which columns you display has no effect on the analysis data stored in the project so you can change the preferences at any time, and the settings on your computer can be different than the ones that other users

have configured on their own computers.

Note: For the simple examples performed in this quick start guide, it is easy to build the system configuration

manually using the software interface. For larger configurations, you can import the data from an Excel file, from

XFRACAS or from another Xfmea/RCM++ project. For information on how to import data, refer to the Importing

and Exporting section of the help file.

Note: The examples in this quick start guide will provide instructions for which columns should be displayed to fit

the needs of the particular stage in the analysis.





Three Complementary Views of the FMEA Data

When you select an item in the system hierarchy that has an FMEA, the FMEA tab in the Analysis paneloffers three complementary views of the information. The analysis information is stored in the repository

and these views simply present the same data in different ways. You can use the buttons at the bottom of

the interface to switch back and forth between the views so you can choose the display that is best suited

for a specific task.

The Hierarchy view tends to be good for viewing a lot of information in a small amount of space.

It can be especially useful when copying and pasting data or when scanning the analysis to find a

particular section of the FMEA.

The Worksheet view allows you to type directly into the worksheet cells and tab through the

analysis as you would in a spreadsheet application such as Microsoft Excel.





The Filtered view presents a sortable list of all records of a particular type. You can choose the

record type that you want to view using the Filter By drop-down list in the upper right corner. You

can then sort the records that appear in this view by clicking a column header. For example, you

may wish to see all cause records sorted by initial RPN, as shown below.

Worksheet View vs. Hierarchy View: When many of us think about FMEAs, the first thing that

comes to mind is the traditional worksheet with the tabular report format that is found in most

published

FMEA

standards.

While

this

worksheet

served

us

well

when

the

most

advanced

tools

atour disposal were an “IBM Selectric” typewriter and a pocket calculator, it can be an inefficient

format for managing large amounts of interrelated data on a computer.

While the worksheet view that mimics the printed layout is available in Xfmea/RCM++ whenever

you choose to use it, the more efficient and flexible hierarchy view will be used in the examples in

this document.




Design for Reliability (DFR) is a process in which a set of reliability

engineering practices are utilized early in a product's design and integrated

into the entire product development cycle. It is widely understood that the

cost of addressing reliability issues increases significantly as a product

progresses through the development cycle (e.g., it is usually much more

expensive to provide support for an unreliable product than it is to improve a product's design). Thus, the effective use of DFR can minimize the costs and

maximize the benefits of producing a reliable product.

3.1 Creating a Customized DFR Planner

You are the leader of a cross-functional team that is responsible for implementing the DFR process for a

new single light pendant chandelier that your company plans to produce. Your first task is to establish a

plan for all of the DFR activities that will be performed throughout the chandelier’s development cycle.

You decide to use the DFR planner feature in Xfmea/RCM++ to record the plan so that:

The information will be readily available to all members of the team.

You can use the software's action management capabilities to notify team members about their

responsibilities and track the completion status.

The plan can be updated with new information when specific analyses are performed using any of

the applications integrated into the Synthesis Platform.

The DFR Planner 3

Project creation

DFR planner







3 The DFR Planner


Objectives

Use Xfmea/RCM++ to create a new project in a Synthesis repository. Use a template to add a DFR planner to the top-level item in the system hierarchy and begin

customizing it to fit the specific process used within your company.

SolutionYou know that you're going to store the DFR planner together in the same project with the design FMEAs

that your team will perform on the chandelier's assemblies/components. So your first step is to create a

new project in Xfmea/RCM++ that uses the configurable settings your organization has standardized upon

for DFMEAs. With the repository open, you choose Project > Management > Create Project and set the

project properties as shown in the following picture.

You choose Grouped Effect and Causes from the FMEA Structure drop-down list. As discussed on

page 28 in Chapter 5, the software offers a choice of three ways that the effect and cause records can be

displayed in an FMEA. You choose the Grouped Effects and Causes structure so you can display causes

and effects at the same level of the hierarchy under the failure mode that they are both associated with.

Then you choose RS DFR Focus from the Select Profile from Library drop-down list. This copies the

predefined settings from the active library (including DFR planner templates) so they can be used in the

current project.

Note: Instead of creating your own project, you can open the “Chandelier1 ‐ DFR Planner” project in the quick

start repository to see the DFR planner that is created in this chapter.





In the Project Category drop-down list, you accept the default Not Categorized option.

When you create a new project, the software automatically adds the first item to the system hierarchy. To

rename this item to “Chandelier,” you select the item and then type inside the Item Name field of the

Properties tab. You also enter additional properties to describe the system, as shown next.

Finally, you right-click one of the system hierarchy column headers and choose Customize Columns. For

this project, you choose to enable only the DFR Planner, Risk Discovery, Risk Discovery Details and

FMEA columns, as shown next.

Tip: This example uses the default options that are shipped with the software for the Project Category and the

Select Profile from Library drop‐down lists. For your own implementation, it is likely that you (or someone else in

your organization) will configure these lists to meet the specific needs of your organization.



3 The DFR Planner


Create the DFR Planner

To add the DFR planner, you return to the system hierarchy, select the chandelier and choose Insert >Planning > Add DFR Planner.

The software gives you the option to start from a saved template or create a new plan. Because this is the

first DFR planner that your organization has created in Xfmea/RCM++, you decide to base it on one of the

predefined templates installed with the software and then customize it to fit the specific process used

within your company. You choose the template called “DFR Template2 - Basic Plan” and enter 3/1/2022

in the Set Start Date field, as shown next.

Note: To ensure that you will be able to see some of the “status” functionality that is built into the software, this

example uses a date that is far in the future. By using a future date, the statuses all show as “Not Started” (rather

than “Overdue”), which is more likely to appear in a new plan.





When you click OK , the software adds a new DFR Planner tab to the Analysis panel and puts the icon

into the DFR Planner column of the system hierarchy.

Adding Details to the DFR Planner

To begin adjusting the draft that was created automatically from the template, you do the following:

First, since you are about to modify the template and have already created a DFR plan, you remove

the gates called “Modify This Template” and “Create the DFR Plan” by selecting each gate and

pressing DELETE. In addition, since you don’t plan on adding any new gates, you also remove

the placeholder “Add...” gates.

Removing the “Add...” gates left large gaps throughout the plan. For example, the top-level

“Concept Phase” gate is still due on 3/28, but its last sub-gate, “Environment & Usage,” is due a

week earlier than that. You remove all of these gaps by choosing DFR > Tools > Remove Gaps in

Dates.

A window will appear asking if you want to remove the gaps and assign precedents to each

gate. Since every gate must have an assigned precedent in order to remove all gaps, you click

Yes.

Using the DFR Planner: In the DFR planner, the structure of the entire DFR process can be

represented using gates, sub‐gates and actions arranged in a tree‐based configuration. Each gate

represents a phase of the DFR process (e.g., the design phase), and each sub‐gate represents a

milestone that must be accomplished during that phase (e.g., part of the design phase might be

performing

DFMEAs).

Actions

can

also

be

linked

to

gates

and

thus

incorporated

into

the

DFRprocess; they represent activities that are assigned to specific people and can be tracked like any

other action in a Synthesis project.

When you double‐click a gate or action, you will be able to edit some of its properties, such as its

description, duration, etc. When a value cannot be edited directly (because the property is

inherited from another gate), it will appear in gray. For example, the software assumes that a new

phase will begin as soon as the immediately prior phase is due. Thus, if the first top‐level gate has a

due date of

3/1/2022,

then

the

software

will

automatically

set

the

start date

of the

next

top

‐level

gate to 3/1/2022.

The status of each gate (i.e., Not Started, In Progress, Complete and Overdue) is also set

automatically using the various dates associated with the gate. For example, a gate with an entered

completion date is considered Complete, and an incomplete gate that was due prior to the current

date is considered Overdue. As a result, you can use the DFR planner to track the progress of the

entire DFR process as you update the properties of individual gates.



3 The DFR Planner


Some of the early DFR gates have already been completed, so under the “Concept Phase” gate:

You double-click the sub-gate called “Requirements & Goals” and enter 3/10/2022 for theCompletion Date. When you click OK to save the changes, you can see that the Status column

now displays the icon to show that this task has been completed.

Then you enter the completion date (3/20/2022) for the sub-gate called “Environment &

Usage” and save the changes. The icon is now displayed for the entire “Concept Phase”

gate because all of its sub-gates are marked complete.

Next, under the “Design Phase” gate:

You double-click the “Change Point / Risk Discovery” sub-gate and change the start date to

indicate that, on 3/22/2022, the team will start identifying which items in the chandelier's

system configuration should have an assembly- or component-level FMEA performed. You

also change all the fields under the Gate heading and the duration of the gate, as shown next.





After you click OK to save the changes, you see that the new due date for the preliminary risk

assessment automatically updates the start date for the DFMEA, and so on down the rest of the

sub-gates in this phase.

You double-click the “DFMEA” gate and change the Duration to 21 days.

Shortening the durations of gates under “Design Phase” left a long gap between the “Design

Phase” due date and that of its last sub-gate. To remove this gap, you double-click the “Design

Phase” gate and change the due date to match that of “Update DFMEA” (i.e., 5/17/2022). Since the

duration of “Design Phase” is now shorter, the remaining gates in the plan are automatically

updated to begin earlier.

The modified plan is shown next.

As your team works through the stages in the DFR process, you will continue to update the plan.






One of the early steps in any DFR process is to identify the assemblies and

components that comprise the system. Xfmea/RCM++ makes it easy to

import information from an outside source (e.g., “Bill of Materials”) or

build the configuration directly within the software. Once the assemblies

and components have been identified, the team may wish to perform a

“preliminary risk assessment” (for a new design) or a “change point

analysis” (for a new version of an existing design) in order to decide which items need to be analyzed.

Xfmea/RCM++ offers a choice of two configurable methods for this analysis: questions or ratings.

This chapter shows how to define the system configuration directly within the software interface, and

demonstrates how to perform preliminary risk assessments using a series of yes/no questions designed to

determine whether further analysis may be beneficial.

4.1 System Hierarchy

Since the “Concept Phase” gates in your DFR planner have already been completed (see Chapter 3), the

next gate is “Preliminary Risk Assessment.” To prepare for the analysis, you must first record the system

configuration for the chandelier in Xfmea/RCM++, and then organize a meeting with the design team to

perform the preliminary risk assessments.

System Hierarchy

and

Risk Discovery 4

System hierarchy

Risk discovery







4 System Hierarchy and Risk Discovery


Objectives

Create the system hierarchy that shows the chandelier’s assemblies and components.

Perform a preliminary risk assessment to determine which assemblies/components require analysis

by the FMEA team.

SolutionThe chandelier is made up of the following assemblies and components:

To add each of the three assemblies under the “Chandelier” item that you defined when you created the

project (see Chapter 3), you select the top-level item and choose System Hierarchy > Add > Add Next

Level Item then type the appropriate label into the Item Name field on the Properties tab in the Analysis

panel.

Note: Instead of creating your own project, you can open the “Chandelier2 ‐ Risk Discovery” project in the quick

start repository.

Tip: If you happen to add the item to the wrong level in the system configuration, you can promote or demote it

to the right location. For example, if you accidentally add the “Bulb and Socket” assembly in the next level under

“Wiring,” right

‐click

the

item

and

choose

Move

> Promote

from

the

shortcut

menu.





To add each of the third-level components, you click the “Bulb and Socket” item and choose System

Hierarchy > Add Next Level Item then type the appropriate label into the Item Name field. The

completed configuration will look like the figure shown next.

Risk Discovery Analysis

When the team meets to perform the preliminary risk assessments, you start by reviewing the criteria thatwill be used to evaluate each item. To see the risk discovery questions that have been defined for this

project, you choose Project > Management > Configurable Settings > RD Questions.

The following picture shows the first 10 of the 30 questions that will be available for any risk discovery

analysis performed in this project.





The team agrees to use these questions without modification (you click OK to close the window) and

proceeds to analyze the first assembly (“Frame”). You select the item and choose Insert > Planning >

Add Risk Discovery. The software adds a new Risk Discovery tab to the Analysis panel and puts the

icon into the Risk Discovery column of the system hierarchy.

When they consider each of these issues for the frame, the team answers “yes” to two questions: the frame

is mission-critical and there is a potential for safety-related issues if the frame breaks. To record this in the

risk discovery worksheet, you click the Response cells of the Safety Issues and Mission-Critical rows to

toggle the answers from “No” to “Yes.” For the mission-critical question, you also use the Comments

field to enter the team’s reason for answering “yes” to this question.

Based on these two concerns, the team agrees that the item does warrant further analysis via an FMEA, so

you leave the Mark item for more detailed analysis check box selected.





The completed analysis for the frame looks like the figure shown next:





You also record the analyses performed for the wiring, bulb and socket, as shown in the following

pictures. All four items are also marked for more detailed analysis.









Updating the DFR Planner

Now that you are finished with all the preliminary risk assessments, you can indicate in the DFR planner

that this step of the Design for Reliability process has been completed. You return to the planner by

selecting the chandelier in the system hierarchy and then viewing the DFR Planner tab on the Analysis

panel. After double-clicking the “Preliminary Risk Assessment” gate and entering a completion date, the

plan appears as shown next.




FMEA and FMECA are methodologies designed to identify failure modes

for a product or process, to assess the risk associated with those failure

modes, to rank the issues in terms of importance and to identify and carry

out corrective actions that address the most serious concerns. Typically, a

design FMEA (DFMEA) focuses on concerns about the design itself while a

process FMEA (PFMEA) focuses on issues that may be caused during the

manufacturing process.

This chapter demonstrates the process for performing DFMEAs and

recording the analysis data in the software. The basic analysis process would

be very similar for PFMEAs, although the underlying analysis assumptions,

RPN rating scales, etc. would be different.

5.1 Failure Modes and Effects Analysis (FMEA)

After you have defined the system configuration and performed the preliminary risk assessment (see

Chapter 4), the next gate in the DFR planner is to perform DFMEAs for the items that require further

analysis. You assemble a cross-functional team of experts who have the knowledge necessary to perform

effective FMEAs for the chandelier assemblies/components and then schedule a series of FMEA

meetings. You take responsibility for using the Xfmea/RCM++ software to record the analyses that the

team performs.

Performing Design FMEAs 5

FMEA creation

FMEA structure

Risk priority

numbers

Plots

Actions

Reports

Watch a video

of

this

example

at






5 Performing Design FMEAs


Objectives

Identify and record the functions, failures, effects, causes and controls for each assembly/

component in the chandelier.

Calculate the risk priority numbers then use them to understand the risk in the design and prioritize

issues for corrective action.

Create graphical charts based on the FMEA data.

Identify and record the recommended actions that will be performed to reduce the risk in the

design.

Create print-ready reports for the completed FMEAs.

SolutionAfter the team has performed the preliminary risk assessment, they start to analyze the items. For

example, to start the analysis for the socket, you select the item in the system hierarchy and then choose

Insert > FMEA > Add FMEA. The software adds a new FMEA tab to the Analysis panel and puts the

icon into the FMEA column of the system hierarchy.

In the Add Function window, you define the primary function of the socket by typing the following

description into the Function field:

Provide electricity to bulb

Note: Instead of creating your own project, you can open the “Chandelier3 ‐ DFMEAs” project in the quick start

repository. This guide provides instructions for recording one branch of one FMEA. If you are performing the

complete analysis on your own in a new project, you can enter the rest of the analysis information in a similar

manner or copy/paste the data from the sample project.

5 1 F il M d d Eff t A l i (FMEA)





After adding the text, the Add Function window looks like this:

When you click the Add Failure button, the software saves the new function record and opens the Add

Failure window. You type the following description into the Failure field:

Short circuit occurs

You then click Add Effect button to open the Add Effect window.

For this project, the FMEA Structure is set to Grouped Effects and Causes (see page 11 in Chapter 3),

which means that the Add Effect window allows you to enter and rate more than one effect in the same

data entry window. The effect descriptions will be saved separately in the repository, but they will be

Tip: The Short Description field is a brief version of the record description that appears in diagrams where the full

description would be too long to display. If you do not enter text in this field, the software automatically populates

the field when you save the record (based on the first 50 characters of the record description). Note that the

description fields are not automatically updated if you later change one of them so you must be sure to make the

same changes to both fields if necessary.






displayed together in the analysis views and report output. For the purpose of RPN calculation, the

software will automatically use the highest severity rating that has been defined for any of the possible

effects.

FMEA Structure: The FMEA structure setting on the General page of the Project Properties

window determines how the software will display the effect and cause records in the FMEA

hierarchy.

The Effects

Before

Causes

structure

displays

the

causes

under

the

effects

so

that

you

can

use

different severity ratings when calculating the RPN for different causes that are associated

with the same failure mode (if it is appropriate in the context of the particular analysis).

The Grouped Effects and Causes structure displays causes and effects at the same level of

the hierarchy under the failure mode that they are both associated with. When calculating

the RPN, the software will automatically choose the highest severity rating among all of the

effects that are defined for the failure mode.

The Causes

Before

Effects

structure

displays

the

effects

after

the

causes,

and

requires

that

there can be only one effect record per cause. For example, this may be appropriate for an

RCM analysis where the analysts identify functions, functional failures, failure modes

(i.e., causes) and then effects.

5 1 Failure Modes and Effects Analysis (FMEA)





For this failure mode, you add three effects. You assign initial severity ratings for each effect by clicking

twice in the Initial Severity Column and choosing the severity rating from the drop-down list. With the

effects added and rated, the Add Effect window looks like the one shown next.

You click the Add Cause button and then type the following description into the Cause field for the cause

description:

Corrosion inside the socket

Note: To view the criteria for the severity rating scale that has been defined for this project, you can you click

inside the Initial Severity column then click the Select icon .






The team will assign the initial occurrence and initial detection ratings after they have identified all of the

prevention and detection controls that might affect those ratings. So you click the Add Control button to

open the Add Control window.

You type the following description into the Control field:

Design guideline 1735 on material selection

Then you choose Prevention from the Control Type drop-down list and click OK to save the record and

close the window. The FMEA hierarchy looks like the picture shown next.

Controls: A control is a method or action that is planned or currently in place to reduce or eliminate

the risk associated with a particular failure cause. While the control types are configurable in the

software, practitioners usually classify the controls as “Prevention” or “Detection,” where:

Prevention controls

are

intended

to

reduce

the

likelihood

that

the

problem

will

occur.

Detection controls are intended to increase the likelihood that the problem will be detected

before it reaches the end user.

Analysts will typically consider all of the prevention controls when assigning the initial occurrence

rating to a cause and they will consider all of the detection controls when setting the initial

detection rating.




y ( )


Now that the controls have been defined, the next step is to go back to the cause record and record the

team’s occurrence and detection ratings. You double-click the “Corrosion inside the socket” cause to edit

the record properties.

In the Initial Occurrence field, you open the Select Occurrence window to see the occurrence rating scale

that has been assigned for this project. You choose 5 (1 in 500) and click OK to close the Select

Occurrence window.

You do the same for the Initial Detection field and click 5 - Medium. The following picture shows both

the occurrence and detection scales defined for this project.





You click OK to save the changes in the record and return to the FMEA hierarchy. Note that the calculated

RPN is displayed in the FMEA hierarchy, as shown next.

Then you continue recording the rest of the socket FMEA in a similar manner.

Evaluating the RPNs

Once the FMEA team has identified the functions, failure modes, effects, causes, controls and initial risk

priority numbers (RPNs) for all four of the chandelier assemblies/components, you begin to use the

calculated RPNs as a way to evaluate the risk in the design and to prioritize the issues for corrective

action.

After opening the Chandelier3 - DFMEAs project, you use the Priority Highlights feature to scan through

the FMEAs to see which issues meet the high, medium and low priority thresholds. To show the team

what thresholds have been established in this project, you choose Project > Management >

Configurable Settings > Interface Style to open the Edit Project Interface Style window then use the

Tip: Remember

that

while

the

quick

start

guide

describes

the

steps

for

only

one

branch

of

one

FMEA,

the

“Chandelier3 ‐ DFMEAs” project contains the completed FMEAs for all four assemblies/components. For the rest of

this example, you will be working with the entire data set available in the sample project.





navigation panel to display the FMEA > RPNs page. As shown below, when the highlight colors are

turned on for the analyses in this project, the issue will be colored green if the RPN is less than or equal to

30, yellow if the RPN is 31 to 299 and red if the RPN is 300 or higher.

The team accepts these settings so you click OK to close the interface style. Then you open an FMEA and

choose FMEA > Tools > Highlight Priority to turn on the priority highlights.





The team then looks at the highlighted RPNs in each FMEA. For example, the following picture shows the

calculated RPNs for the full socket FMEA, where one issue is highlighted in green to indicate low priority

and the rest are highlighted in yellow to indicate medium priority.

To look at the RPNs in a second way, you use the Filtered view to see lists of all the causes in each FMEA

sorted by RPN. For example, to create a list for the bulb FMEA, you select the item in the system

hierarchy then click the Filtered tab at the bottom of the Analysis panel and choose Causes from the

Filter By drop-down list in the upper-right corner. To sort the list by initial RPN, you click inside the





header for the RPNi column. As shown in the picture below, three causes in this FMEA are highlighted as

high priority (red) and two are medium priority (yellow).

For a third perspective, you choose Home > Reporting > Plots to generate some graphical charts based

on the analysis data. When prompted to specify which data will be reflected in the charts, you click the

check box in the column header to select all items, as shown next, and then click OK .





In the Plot Viewer window, you choose to create an RPN (Pareto) chart that displays the top ten issues

ranked by RPN. As shown next, when you point to a bar in the chart, the software displays the cause

description, the name and number of the item that the FMEA belongs to (in parentheses) and the RPN.

Next, you change the plot type to Occurrence/Severity Matrix, which displays the severity ratings on the

horizontal axis and occurrence ratings on the vertical axis, then plots each cause at the intersection of its

severity and occurrence ratings. You can see that when the analysis considers only the S and O

components of the RPN equation, all of the issues fall into the “High Priority” range. Once again, pointing

Tip: The Plot Type field allows you to select which chart will be displayed. When a bar chart is selected, the

Display Range area allows you to specify the number of records you want to be displayed in the plot. For example,

since there

are

17

cause

records

in

the

chandelier

FMEAs,

you

could

specify

to

view

records

1 through

5,

1 through

10, 1 through 17, etc.





to a shape in the matrix displays the name of the failure cause and other relevant details, as shown in the

following picture.

After you are done reviewing the plots, you close the Plot Viewer window.

Managing Recommended Actions

The next step is to identify, assign and track the completion of the recommended actions that will help to

reduce the risk associated with potential failures.

The FMEA team identifies the actions that need to be performed to improve the chandelier design, and

you record the details in the appropriate locations within each FMEA. For example the team decides to

address the “Corrosion inside the socket” issue by developing a corrosion test protocol.





To create the action, you select the socket in the system hierarchy. Then you return to the Hierarchy view

of the FMEA and select the “Corrosion inside the socket” cause. After you choose FMEA > FMEA

Records > Actions to open the Add Action window, you set the action properties as shown in thefollowing picture.





Generating a Report

When you are ready to generate a print-ready report that displays the analysis information, you choose

Home > Reporting > Reports. The Reports window provides a choice of predefined and custom report

forms that can be included in a report document generated in either Microsoft Word or Excel.

You decide that the report should show:

The rating scales used

The risk discovery questions and answers

An FMEA spreadsheet that is consistent with Form A in the published AIAG FMEA-4 guidelines

A list of the causes ranked by initial RPN

A list of the recommended actions

To build the desired report, you do the following:

Select the check box in the header of the Select Items area to specify that the data from all four

FMEAs will be included in the report.

Click the Exclude All button (<<) to remove any existing reports in the Selected Reports area.

Actions Management in Xfmea/RCM++: One of the most costly mistakes among FMEA

practitioners is the failure to follow up and track the completion of recommended actions. Xfmea/

RCM++ provides multiple features to help your organization implement the improvements that are

identified during the FMEA activity. For example:

You can assign an action to any user with an account in the Synthesis repository and that

action will display in the user's My Portal.

You can generate e‐mails, both automatically and manually, when certain conditions are met

(e.g., action creation, action modification, action completion).

You can generate reports about the actions defined in the analysis project, such as a list of

actions sorted by due date or action category.

Actions are Synthesis resources, which means that they can be used in any FMEA within the

same project. Changes made in one place are reflected everywhere the action is used.





Select Excel Spreadsheet in the Select Output Type area.

Select the five desired report forms from the Available Reports area and move them to the

Selected Reports area.

For example, to include the causes ranked by initial RPN, you select the Causes report in the FMEA

Records section in the Available Reports area. To move it to the Selected Reports area, you click the

report and then drag it to the desired location in the Selected Reports area. To sort it by initial RPN,

you click inside the Sort By column and choose Initial RPN from the drop-down list.

After selecting the reports, the window will look like this:

You click Generate Report and specify the name and location where the report file will be saved. The

report will then open automatically in Microsoft Excel.






After you are finished creating all the FMEAs and performing all the tasks associated with that, you can

indicate in the DFR planner that this step of the Design for Reliability process has been completed. Youreturn to the planner by selecting the chandelier in the system hierarchy and then viewing the DFR Planner

tab on the Analysis panel. After double-clicking the “DFMEA” gate and entering a completion date, the

plan appears as shown next.






The innovative failure modes and reliability analysis (FMRA) tool in

Xfmea/RCM++ enables you to use the information from the system

hierarchy and FMEAs to perform a variety of reliability-related analyses.

One application for this tool is to generate a preliminary quantitative

estimate of the system’s baseline reliability using the qualitative occurrence

ratings specified in the project’s FMEAs.

Specifically, you can use the occurrence ratings to assign quantitative

models to describe the probability of failure due to each failure cause

identified in the FMEA, and then you can estimate the system’s reliability

based on those models. As better information about the system becomes

available, you can then update the FMRA to improve your understanding of

the system’s reliability and the components/failure modes that have the

biggest impact on that reliability.

6.1 Using the FMRA to Generate a Baseline Reliability Estimate

After completing the assembly- and component-level FMEAs (see Chapter 5), the next step in the DFR

planner is to generate a baseline reliability estimate for the chandelier. Since little data is available at this

point in the process, you will start by using the occurrence ratings assigned in the FMEAs.

Objectives

Display the FMRA interface and customize it so you only see the columns that are relevant for

estimating the system’s reliability.

Produce a first draft of the FMRA and use it to generate a preliminary estimate of the system’s

baseline reliability.

FMRA‐Reliability

Estimation 6

Failure modes

and reliability

analysis (FMRA)

Estimating the

system reliability

Project baselines

FMRA vetting



6 FMRA ‐ Reliability Estimation

C b li f h i j “ i ” b f b i dj i h






Create a baseline of the entire project to use as a “restore point” before you begin adjusting the

analysis.

Begin the “FMRA vetting” process by reviewing and updating the first draft.

Solution

First, you choose View > FMRA > Show FMRA. The FMRA interface shows each item from the systemhierarchy, along with all the functions, failures and causes that are defined in the FMEAs. The columns in

the FMRA display various kinds of information and analysis results for each record. To select which

columns to show on your computer, you right-click a column header in the FMRA and choose Customize

Columns. You only want to see the columns that are relevant to estimating the system’s reliability (and

the reliabilities of its components), so you make the selections shown next.

When you return to the FMRA hierarchy, you click the system (i.e., the top-level item) and enter 5000 for

the Operating Time on the properties tab to estimate the reliability at 5,000 hours.

Note: Instead of creating your own project, you can open the “Chandelier4 ‐ FMRA Draft” project in the quick

start repository to see the first draft of the FMRA. The “Chandelier5 ‐ FMRA Revised” project contains the updated

version of the analysis.


N t h P j t > M t > C fi bl S tti > O t th




Next, you choose Project > Management > Configurable Settings > Occurrence to see the occurrence

scale that is in effect for this project and confirm that the settings will allow the software to create

appropriate probability of failure models for use in the FMRA.

The probability of failure model that is associated with each rating in the scale will be determined by the

number in the Quantitative Value column and the option selected in the Treat Quantitative Values As

area.

For example, if Fixed probability of failure (Q) were selected, then a cause with a rating of 4 (1 in 1,000)

would always be assigned a fixed probability of 0.1% (or 0.001) regardless of the operating time.

However, in this case, you know that the FMEA team assigned occurrence ratings based on the probabilitythat the failure would occur by 1,000 hours of operation, so it is possible to use a time-dependent

exponential distribution instead of a fixed probability. This will allow the software to calculate the

probability of failure for any operating time specified for the analysis (which is 5,000 hours in this case).

You make sure the Exponential distribution option is selected and you set T to 1,000 hours. With this


setting an exponential model will be built for each rating using the probability of failure entered in the




setting, an exponential model will be built for each rating using the probability of failure entered in the

Quantitative Value field and the time specified for T .

After confirming that the quantitative values reflect the criteria that the team used for the FMEAs, you

click OK to close the window. The next step is to configure the software so each cause is automatically

assigned an appropriate model based on the initial occurrence ratings from the FMEAs. While you could

do this by modifying the reliability policy for each cause individually (on the Properties tab), you know it

Probability Models in the FMRA: If you choose to associate exponential models with the

occurrence ratings, the parameter for each model will be estimated using the same calculation

performed in the Quick Parameter Estimator. The probability of failure (Q) and time (T) that you

specified in the scale are used to solve for the lambda parameter of the exponential distribution as

follows:

Note that if you used the Application Setup window to configure the software to use mean time to

failure (MTTF) as the parameter of the exponential distribution instead of lambda, the application

will first

solve

for

lambda

and

then

calculate

the

reciprocal

of

lambda

to

obtain

the

MTTF.

1 Q T – R T e t – = =

1 Q T – ln –

t ----------------------------------- =


will be faster to update all the causes simultaneously by choosing FMRA > RAM Analysis > Policy




will be faster to update all the causes simultaneously by choosing FMRA > RAM Analysis > Policy

Update. In the window that appears, you select Cause and choose Based on Initial Occurrence from the

drop-down list.

After you click OK , the reliability policy type for each cause record is changed to Based on Initial

Occurrence. Now, when you click any cause record, you can see the updated policy and view information

about the assigned model on the Properties tab.

For example, for the “Corrosion” cause shown next, the name of the model indicates that it is based on an

Occurrence rating of 6, which in this project corresponds to a probability of 1 in 100 at 1,000 hours. The

information in brackets indicates that the model uses a 1-parameter exponential distribution (EX1), andthe value of lambda is 0.000010.


You scan through the FMRA to make sure that all of the models were assigned properly and then choose




ou sc oug e o e su e o e ode s we e ss g ed p ope y d e c oose

FMRA > RAM Analysis > Calculate (Reliability) to solve for the system’s baseline reliability. To color-

code the reliability values (which uses a gradient from green to red to indicate which are the highest valuesand which are the lowest), you choose FMRA > RAM Analysis > Highlight.

The results are displayed in the FMRA as shown next. (In this picture, the records for the frame and wiring

are hidden, but they can be shown by clicking the + button and expanding those parts of the hierarchy.)

The value shown in the Reliability (Analytical) column for the top-level item is the computed baseline

reliability (84.95%) for the entire chandelier at 5,000 hours. To calculate this value, the occurrence rating

for each cause was converted into an exponential distribution. Then these distributions were used to obtain

Note: By default, the software assumes that the occurrence of any one cause is sufficient for the entire system to

fail (i.e., it assumes a reliability‐wise series configuration). If you also have ReliaSoft's BlockSim software, you can

synchronize the FMRA in Xfmea/RCM++ with RBDs or fault trees in BlockSim. You can then use the RBDs/fault

trees to define more complex reliability‐wise configurations in your FMRA, if appropriate. For details, please

consult the Synthesis Platform guide or one of the product help files.


the reliability for each failure mode (i.e., the probability that none of the causes for that failure mode




y ( p y

would occur). Finally, these reliabilities were “rolled up” to get the reliabilities of the components/

assemblies and then the system.

When you generate this first draft of the FMRA, you are aware that the computed values may be far from

the true reliabilities. The next step is to work through the “FMRA vetting” process by carefully reviewing

and updating the analysis with the goal of improving its accuracy and thereby achieving a more accurate

understanding of the system’s baseline reliability.

Note: In this example, since we are assuming a reliability‐wise series configuration, “rolling up” from a lower

level is done by simply multiplying the calculated reliability values at the lower level and assigning the result to the

higher‐level record that is set to “Inherit.” For example, looking at the “Overheat” and “Spike in voltage” cause

records, the reliability is the reciprocal of the cause’s probability of occurrence (i.e., the probability that the cause

will not occur before the specified operating time). So, according to the above FMRA, the probability of the bulb

not overheating before 5,000 hours is estimated to be 99.50%, and the probability of a spike in voltage not

occurring

is

also

99.50%.

Thus, the

probability

of

the

bulb

not

shattering

before

5,000

hours

(i.e.,

the

failure

mode’s reliability) is 99.50% x 99.50% = 99.00%. This is then multiplied by the reliabilities of the other failure

modes under the “Provide light” function to obtain the reliability of the bulb.

FMRA Vetting: In general, the FMRA vetting process involves these two steps:

Cleaning Up

During this step, you review the failure causes that are being considered in the analysis and

perform any cleanup that may be required to make sure the FMRA considers all the causes

that impact

the

system’s

reliability,

but

does

not

consider

causes

that

don't.

Reviewing and Validating Inputs

During this step, you examine the calculated reliability estimates for each record to see if

they fit your expectations. If not, you determine which inputs to the FMRA and DFMEAs

might need to be revised with better information.

The ReliaWiki resource portal provides more information about the FMRA vetting process at:

http://www.ReliaWiki.org/index.php/Using_FMRA_to_Estimate_Baseline_Reliability.


Creating a Baseline

http://www.reliawiki.org/index.php/Using_FMRA_to_Estimate_Baseline_Reliability

http://www.reliawiki.org/index.php/Using_FMRA_to_Estimate_Baseline_Reliability




Before you begin the vetting process, you decide to create a “baseline” of the entire project that you can

restore or roll back to at any point in the future.

To create the baseline, you choose Project > Management > Project Baselines > Create Baseline and

enter text to indicate the purpose of the baseline, as shown next.

You click OK to create the baseline. Then you choose Project > Management > Project Baselines >

Restore Baseline and open the Restore Baseline window to confirm that the baseline was created.

If needed in the future, you will have the option to either roll back the existing project to the state it was in

when this baseline was created (by choosing Overwrite existing project) or to restore the baseline as a


new project that is separate from the one you are currently working with (by choosing Create new




project).

Reviewing and Updating the FMRA

After saving a baseline of the project, you examine the FMRA and look for ways to improve it. One issue

you notice is that the “Bulb wattage too low” failure cause (which occurs if the user installs the wrongtype of bulb) was something that needed to be considered during the FMEA, but it should not affect the

chandelier’s calculated reliability.

To prevent the software from considering this cause, you select it in the FMRA. Then, on the Properties

tab, you set the reliability policy to Define at this level. By default, the software will assign a model with

100% reliability (“Default - Cannot Fail”), as shown next.

By assigning this default model, the cause record will essentially be ignored in the reliability calculations

because the cause reliability will always be 100%.

Tip: The commands in the Project tab of the Ribbon allow you to create or restore any baseline that is associated

with the project that is currently open. In addition, authorized users can choose File > Manage Repository >

Project Baselines in order to view and manage all of the stored baselines for any of the projects in the repository.


Next, you decide to replace the exponential distribution for the frame’s “Corrosion” failure cause with a

d l th t t l fl t th t b h i f thi f il h i




model that more accurately reflects the wearout behavior for this failure mechanism.

After researching this issue, you discover that another design team has analyzed data for the corrosion

failure mode in a similar chandelier frame. The data was fitted to a Weibull distribution with beta = 2.47

and eta = 21,472.35 hours. To use this distribution in the FMRA, you select the cause record and choose

Define at this level as the reliability policy type. Then you double-click inside the Model field, click New

Distribution and enter the information shown next.


After you click OK , the software creates a probability of failure model that uses the distribution you

defined and it assigns this model to the record




defined, and it assigns this model to the record.

Finally, you recalculate the FMRA and see that the system’s reliability estimate is now 87.79%.

Tip: As you can see, you don’t have to use models that are based on the qualitative occurrence ratings from the

FMEAs. The Synthesis Platform allows you to use any probability model that is created within any Synthesis‐

enabled application (e.g., Weibull++, ALTA or BlockSim) or create independent model resources that are not

linked to data sets. In this case, you created a model without linking to an analyzed data set. However, if you had

access to the data for the corrosion failure mode, you could have used Weibull++ to analyze the data and publish

the results as a model. With this approach, if the underlying data analysis ever changes, you have the option to

republish the model with updated information and any Synthesis analysis that uses this model would be updated

automatically as well.



O fi i h tti th FMRA i di t i th DFR l th t thi t f th D i f




Once you finish vetting the FMRA, you indicate in the DFR planner that this step of the Design for

Reliability process has been completed. You return to the planner by selecting the chandelier in theFMRA hierarchy and then viewing the DFR Planner tab on the Analysis panel. After double-clicking the

“Compute Baseline Reliability” gate and entering a completion date, the plan appears as shown next.




The example in Chapter 6 demonstrated how the new failure modes and

reliability analysis (FMRA) tool can be used to estimate a system's baseline

reliability using whatever is currently known about the probability of occurrence for potential failure modes and/or the reliability of the

components. The analysis can continue to be refined and improved over

time as better information becomes available. In RCM++, this tool can also

be used to perform simulation-based calculations that take into account the

maintenance characteristics of a repairable system.

Specifically, RCM++ uses a Synthesis resource called the “Universal Reliability Definition (URD)” to

record not only the reliability characteristics, but also the corrective and preventive maintenancecharacteristics for repairable components. The software uses this information to simulate the operation of

the system for a specified period of operating time in order to calculate a variety of useful metrics,

including the reliability, availability and operating costs. This chapter presents an example in which these

simulation results are used to estimate the availability and operating costs that can be expected from a

specified maintenance strategy. Similar techniques can also be used for comparing different possible

maintenance strategies to determine which approach is expected to provide the desired level of availability

for the minimum cost.

FMRA‐Maintenance

Planning in RCM++ 7

Note: This chapter describes steps for performing calculations that are

available only in RCM++.

Tasks, crews, spare part pools

Maintenance

costs

Availability


http://www.ReliaSoft.tv/rcm/startguide/rcm_qsg_7_1.html

7 FMRA ‐ Maintenance Planning in RCM++

7.1 Using the FMRA to Estimate Availability and Maintenance Costs

http://www.reliasoft.tv/rcm/startguide/rcm_qsg_7_1.html





After you finish vetting the FMRA and obtain the initial design reliability of the chandelier (Chapter 6),

you are asked to estimate the availability of the system and the maintenance costs that are expected to beincurred by the user over 2 years of use.

Objectives

Display the FMRA interface and customize it so you only see the columns that are relevant for

estimating availability and maintenance costs.

Define all the maintenance tasks for the chandelier’s bulb and socket.

Calculate the chandelier’s availability over 2 years (1,000 hours) of usage, and obtain the

maintenance costs that are expected over this time.

Solution

In RCM++ you first choose View > FMRA > Show FMRA. To select which columns in the FMRA to

show on your computer, you right-click a column header in the FMRA and choose Customize Columns.

Note: This example starts with the completed FMRA in the “Chandelier6 ‐ FMRA Final” project in the quick start

repository. Note that because these calculations only need component‐level information (i.e., we are only

concerned with system availability and the maintenance of components, not with the influence of particular

failure modes, etc.), the completed FMRA does not show any FMEA records. Instead, all of the reliability

information is

defined

at

the

item

level,

and

you

will

define

maintenance

characteristics

at

the

item

level

as

well.

To see the FMRA with all the maintenance tasks already defined, see the “Chandelier7 ‐ FMRA Maintenance”

project in the quick start repository. You can follow the steps below to see how the example was performed in the

sample project, or you can copy data/analyses from the project to help you perform the steps on your own.


You only want to see the columns that are relevant to estimating availability and maintenance costs, so

you make the selections shown next.




Because you wish to estimate the availability and maintenance costs at 2 years (or 1,000 hours) of

operation, you click the top-level system in the FMRA and enter 1,000 for the Operating Time on the

Properties tab.

Since the owner of the chandelier is unlikely to repair it when it fails due to problems with the frame or

wiring, only the maintenance of the bulb and socket will be considered. To consider the maintenance tasks

associated with these components, you will need to create and define a maintenance task resource for both

the bulb and the socket.


Defining a New Maintenance Task for the Bulb

To define a maintenance task for the bulb, you need to add a task resource to the Universal Reliability




, y y

Definition (URD) that’s currently assigned to the bulb. To do this, you select the bulb in the FMRA and,on the Properties tab, you double-click inside the Corrective Task field.

In the Corrective Task Wizard that appears, you click the Add icon to open the Maintenance Task

window.

In this case, maintenance of the bulb will consist of all the tasks associated with replacing it. The

following is assumed about the bulb’s replacement:

The bulb will be replaced only after it has already failed, and it will be replaced by the owner of the

chandelier.

The owner does not keep spare bulbs on hand and will have to purchase one from a nearby home

improvement store. The total time for the trip is 2 hours on average (with a standard deviation of 20 minutes), and

the cost of transportation (fuel, etc.) is $6 on average (with a standard deviation of $0.50).

The cost for a new bulb is $5 on average (with a standard deviation of $0.50).


Once a spare is obtained, the owner will have to retrieve a ladder so he can reach the failed bulb.

On average, it takes 10 minutes (with a standard deviation of 2 minutes) to retrieve and position the

l dd




ladder.

Once the ladder is in place, it takes an average of 5 minutes (with a standard deviation of 1 minute)

to replace the bulb.

This is the information that you want to include in the bulb’s maintenance task resource. To define a task

with all these properties, you start by choosing Upon item failure from the Start corrective task drop-

down list. This indicates that the task will begin only when the bulb fails.

Next, you double-click inside the Task duration field to define a model for the time it takes to change the

bulb. You enter the information shown next.

After you click OK , the model for the replacement time appears in the Maintenance Task window, as

shown next.


Next, you want to define a crew so you can indicate who will perform the task and take into account the

time required to retrieve the ladder. You double-click inside the Crew for task field and click the Add

icon The Crew window appears as shown next




icon. The Crew window appears as shown next.

You enter Owner in the Crew Name field to indicate who will be performing the replacement. Then you

double-click inside the Logistic delay field to define a model for the time required to retrieve the ladder.

In the Model Wizard that appears, you enter the following information.


After you click OK , you can see the model that was defined for the ladder, as shown next.




You click OK to close the Crew window and return to the Maintenance Task window.

What you need to do now is take into account the transportation-related costs and delays, as well as the

cost of the spare bulb itself. You double-click inside the Spare Part Pool field and then click the Add

icon to create a new spare part pool resource. You enter Bulb Purchase for the spare part pool’s name.

Then, to define a model for the bulb’s cost, you double-click inside the Direct cost per dispensed item

field, then you enter the information shown next and click OK .


To define a model for the round trip time required to get to the home improvement store, you double-click

inside the Logistic time for spare acquisition field and enter the information shown next. (Note that both

mean and standard deviation are entered in minutes.)




mean and standard deviation are entered in minutes.)

After you click OK , you can see the models defined for the bulb’s price and the drive to the store.


The only part of the task left to define is the cost of transportation to the store (e.g., fuel). You click OK to

close the Spare Part Pool window and return to the Maintenance Task window. Then you double-click

inside the Cost per task field under the Additional Costs to Consider header.




p

In the Model Wizard that appears, you enter this information.


After you click OK , you can view all the properties defined for the bulb replacement task, as shown next.




You save the new task by clicking OK , and now you can see that the new task is part of the bulb’sreliability policy.


Defining a New Maintenance Task for the Socket

To define a maintenance task for the socket, you follow steps similar to those described above.




In this case, maintenance of the socket will consist of all the tasks associated with hiring an electrician to

replace it. The following is assumed about the socket replacement:

The task is performed only after the socket fails, and it will be performed by an electrician.

On average, it takes 4 days (with a standard deviation of 1 day) for the electrician to arrive after the

owner calls to schedule an appointment.

Once he arrives, the electrician will charge $90 per hour, plus a fixed fee of $50 per visit. In addition, there is a $50 charge for the spare socket that will be used for the repair.

There is also a 50% chance that the electrician will not have a spare socket available. If no

socket is available, the electrician will drive to a nearby home improvement store (the same

store where the owner buys spare bulbs) to purchase one.

It takes an average of 60 minutes (with a standard deviation of 20 minutes) to perform the socket

replacement.

You start by choosing Upon item failure from the Start corrective task drop-down list. Next, you

double-click inside the Task duration field to define a model for the time it takes for the electrician to

repair the socket. You enter the information shown next.


After you click OK , the model for the replacement time appears in the Maintenance Task window, as

shown next.




Next, you want to define a crew so you can take into account how much the electrician charges and how

long it takes him to arrive after you first schedule an appointment. You double-click inside the Crew for

task field and click the Add icon. In the Crew window that appears, you enter Electrician for the crew

name. Then you double-click inside the Direct cost field to specify how much the electrician charges per

hour. In the Model Wizard that appears, you click the New Constant button.

Then you enter the information shown next.

To define the flat fee that the electrician charges per visit, you double-click inside the Cost per incident

field and click the New Constant button. Then you enter Crew - Per Incident for this model’s name and

enter 50 in the Constant Cost field.


To define a model that describes the time it takes for the electrician to arrive after you first call to schedule

an appointment, you double-click inside the Logistic delay field and enter this information.




With the crew resource now defined, you can review its properties in the Crew window, as shown next.

Next, you need to create a spare part pool to specify how much a spare socket costs, how likely it is that

the electrician won’t have a spare available and, if he doesn’t, how long it will take to obtain a new one. So

you double-click inside the Spare Part Pool field and click the Add icon. In the window that appears you


enter Socket Part for the spare part pool name, and then you double-click inside the Direct cost per

dispensed item field and then click the New Constant button.

In the Model Wizard that appears you enter Socket Price for the model’s name and enter 50 in the




In the Model Wizard that appears, you enter Socket Price for the model s name and enter 50 in theConstant Cost field. Then you choose Fixed probability of stockout from the Spare acquisition type

drop-down list. This indicates that the probability that the electrician will not have a spare socket available

is always the same. In the Fixed probability value field, you specify that the probability of having no

spare available is always 0.5.

If the electrician does not have a spare on hand, he will have to take the time to drive to the home

improvement store and buy a new one. So you select the Can obtain emergency spares if needed check

box under the Emergency Spare Provisions heading. Then you double-click inside the Required time

for emergency spares field and click the Select Existing icon.

Since the “Trip Time” model was already created to define how long it would take the owner to go to the

store and buy new bulbs, you use this same model for this field. After you select the model, the Spare Part

Pool window now looks like this.


You click OK to save this resource and include it in the maintenance task. Now, in the Maintenance Task

window, you can view all the properties defined for the socket repair, as shown next.




After you click OK to save the entire task resource, you can see that the new task is part of the socket’s

reliability policy in the FMRA.

Estimating the Availability and Maintenance Costs

Now that maintenance tasks have been defined for the bulb and socket, and since updated reliability

models have already been assigned to each item in the system hierarchy, you can use simulation to

estimate the availability of the chandelier and the operating costs that are expected over 1,000 hours of

operation.


To perform the calculation, you choose FMRA > RAM Analysis > Simulate (Availability). The

Simulate window will appear so you can review or edit the options for how the simulation-based values

will be obtained. You choose to perform 2,000 simulations, and you select to use a starting seed of 1. (The

starting seed will ensure that you get the same result every time you perform the simulation )




starting seed will ensure that you get the same result every time you perform the simulation.)

Then you click OK to perform the simulation.

To color-code the availability values using a gradient from red to green (where red is the lowest

availability and green is the highest), you choose FMRA > RAM Analysis > Highlight. The FMRA

simulation results appear as shown next.

As you can see, the total operating cost for the chandelier is expected to be $436.18 over 1,000 hours of

operation. Almost all of this is due to costs resulting from the socket’s maintenance ($435.96). In addition,

the total availability of the chandelier is 98.94%. This means that the chandelier is estimated to beavailable for 989 hours (98.95% x 1,000 hours) during its 1,000 hours of operation.

T diti l RCM A l i 8




Traditional reliability centered maintenance (RCM) analysis provides a

structured framework for analyzing the functions and potential failures for a

physical asset (such as an airplane, a manufacturing production line, etc.) in

order to develop a scheduled maintenance plan that will provide an

acceptable level of operability, with an acceptable level of risk, in an

efficient and cost-effective manner.

The RCM++ software is shipped with predefined profiles that fit the major

published standards and logic diagrams for such analyses (e.g., ATA MSG-3

and SAE JA1011/1012). In general, the analysis methodology described inthese standards involves four basic steps: 1) equipment selection,

2) functional failure analysis, 3) failure effect categorization and

4) maintenance task selection.

8.1 Reliability Centered Maintenance (RCM)

Now that the design for the chandelier is complete and the product has entered production, you begin

working with the manufacturing team to assist with process FMEAs (PFMEAs), maintenance planning

and other relevant tasks. Your next assignment is to explore the possibility of using traditional RCM

Traditional RCM

Analysis

for a Conveyor Belt 8

Note: This chapter describes the steps for performing a reliability centered

maintenance analysis with failure effect categorization and maintenance

task selection. This functionality is available only in RCM++.

Project creation

Equipment

selection

Functional failure

analysis

Failure effect

categorization

Maintenance task

selection

Reports


http://www.ReliaSoft.tv/rcm/startguide/rcm_qsg_8_1.html.

8 Traditional RCM Analysis for a Conveyor Belt

analysis techniques to develop effective scheduled maintenance plans for the manufacturing equipment.

You begin by conducting a pilots project to perform a simple RCM analysis for a conveyor belt. You

assemble a cross-functional team of experts to participate in the analysis, and you take responsibility for

recording the analysis results in Xfmea/RCM++.






g y

Objectives

Create a project and define an item in the system hierarchy.

Use the equipment selection questions from the SAE JA1012 guidelines to determine whether

RCM analysis should be performed for the item.

Perform a functional failure analysis.

Use the failure effect categorization (FEC) logic from the SAE JA1012 guidelines to classify the

effects of each potential functional failure.

Use the associated maintenance task selection logic to identify and record the recommended

scheduled maintenance tasks.

Create print-ready reports for the completed analysis.

Solution

The first step is to create a new project in RCM++ that uses the configurable settings your organization

has standardized upon for RCMs. With the repository open, you choose Project > Management > CreateProject and set the project properties as shown in the following picture.

Note: Instead of creating your own project, you can open the “Conveyor Belt ‐ RCM” project in the quick start

repository. This guide provides instructions for recording one branch of the functional failure analysis. If you are

performing the complete analysis on your own in a new project, you can enter the rest of the analysis information

in a similar manner or copy/paste the data from the sample project.





You choose Effects Before Causes from the FMEA Structure drop-down list. As discussed on page 28

in Chapter 5, the software offers a choice of three ways that the software can display the effect and failure

mode (cause) records in a functional failure analysis. While some RCM practitioners use the Causes

Before Effects structure, your organization uses the Effects Before Causes structure because you prefer not to duplicate the effect (and the FEC value) when a functional failure has the same effect regardless of

which specific failure mode caused it.

You choose SAE RCM (4 Categories) from the Select Profile from Library drop-down list. This copies

the predefined settings (including the RCM logic diagrams) from the active library so they can be used in

the current project.

In the Project Category drop-down list, you accept the default option of Not Categorized.

Tip: This example uses the default options that are shipped with the software for the Project Category and the

Select Profile from Library drop‐down lists. For your own implementation, it is likely that you (or someone else in

your organization) will configure these lists to meet the specific needs of your organization.


When you create a new project, the software automatically adds an item to the system hierarchy. To

rename the item to “Conveyor Belt,” you select the item and then type inside the Item Name field of the

Properties tab. You also enter some additional properties to describe the item, as shown next.




Finally, you right-click one of the system hierarchy column headers and choose Customize Columns. For

this project, you choose to enable only the Risk Discovery and FMEA columns.


A Note

About

RCM

Terminology

in

the

Software:

RCM++

combines

RCM

capabilities

and

FMEA biliti t th i th ft i t f Alth h th i il iti




Equipment Selection

When the team convenes for the first meeting, you start by reviewing the criteria that will be used to

determine whether RCM should be performed for the item. To see the equipment selection questions thathave been defined for this project, you choose Project > Management > Configurable Settings > RD

FMEA capabilities together in the same software interface. Although there are many similarities

between the two analysis methodologies, there are some basic differences in the terminology and

conventions that affect the application interface. As you are using the software, it may be helpful to

note that:

FMEA and Functional Failure Analysis: Regardless of whether you are performing an RCM

analysis or an FMEA, all of the information related to the functions and failure modes will be

displayed in

the

FMEA

tab

of

the

Analysis

panel,

and

you

will

use

the

commands

in

the

FMEA

tab of the Ribbon to manage this information. In other words, the term “FMEA” is often used

within the software interface in place of “functional failure analysis.”

Functional Failures, Failure Modes and Causes: Although the property names within the

software are fully configurable to fit the specific analysis terminology used by your

organization, the Ribbon commands, icons and window names are not. When a name is not

configurable, the term “Failure” is used to refer to the second level in the analysis hierarchy

and the

term

“Cause”

is

used

to

refer

to

the

fourth

level.

If

you

are

performing

a functional

failure analysis, you might refer to these levels as the “Functional Failure” and “Failure

Mode.” If you are performing an FMEA, you might refer to these levels as the “Failure Mode”

and “Cause.”


Questions. The following picture show the questions that will be available for any equipment selection

analysis performed in this project.




The team agrees to use these questions without modification (you click OK to close the window) and

proceeds to analyze the conveyor belt. You select the item and choose Insert > Planning > Add Risk

Discovery. The software adds a new Risk Discovery tab to the Analysis panel and puts the icon into

the Risk Discovery column of the system hierarchy.

When they consider each of these issues for the conveyor belt, the team answers “yes” to two questions:

the conveyor belt’s failure could have an operational effect and there is a potential for a significant

economic impact if the conveyor belt breaks. To record this in the risk discovery worksheet, you click the

Response cells of the Operational and Economic rows to toggle the answers from “No” to “Yes.” As

shown in the following picture, you also use the Comments field to enter the team’s reasons for

answering “yes” to the questions.


Based on these two concerns, the team leaves the Mark item for more detailed analysis check box

selected and the software displays a red icon in the Risk Discovery column of the system hierarchy.

Functional Failure

Analysis

To perform a functional failure analysis to the conveyor belt you select the item and then choose Insert >




To perform a functional failure analysis to the conveyor belt, you select the item and then choose Insert >

FMEA > Add FMEA. The software adds a new FMEA tab to the Analysis panel and puts the icon

into the FMEA column of the system hierarchy.

In the Add Function window, you define the primary function of the conveyor belt by typing the following

into the Function field:

Convey solid material from one location to another at 1000 pounds per

hour while maintaining system integrity and providing feedback to the

distributed control system (DCS).

After adding the text, the Add Function window looks like this:


Tip: The Short Description field is a brief version of the record description that appears in diagrams where the full

description would

be

too

long

to

display.

If

you

do

not

enter

text

in

this

field,

the

software

automatically

populates

the field when you save the record (based on the first 50 characters of the record description). Note that the

d f ld ll d d f l h f h b k h




When you click the Add Failure button, the software saves the new function record and opens the Add

Failure window. You type the following description into the Functional Failure field:

Conveys no material

You then click the Add Effect button to open the Add Effect window.

In the Add Effect window, you type the following description in the Effect field:

Loss of production

To perform the failure effect categorization (FEC) for this effect, you click the Effect Categorization

button.

As shown below, you answer Yes to Question 1 and No to Question 2. Using these answers, the software

automatically categorizes the effect as 2 - Evident Economic Consequences.

description fields are not automatically updated if you later change one of them, so you must be sure to make the

same changes to both fields if necessary.

Tip: You can also use the drop‐down list in the Category field to choose the category directly. In this case, the

software automatically sets the answers for you.


Instead of recording the reason for each Yes/No answer, you use the Remarks field to record the reason

why the team chose this category: “Will have an impact on other equipment and will result in loss of

income.”




You click OK to close the Failure Effect Categorization window, then you click Add Cause. In the AddCause window, you type the following description in the Failure Mode field:

Belt conveyor bearing worn or seized due to improper lubrication

You then click Add Cause to add a second failure mode called:

Chain drive failure due to chain wear and/or damage


You click Add Failure to open the Add Failure window and record the second potential failure (“Conveys

less than the required rate”). Then you continue recording the rest of the analysis in a similar manner.

When completed, the analysis hierarchy will look like the following:




Selecting and Defining a Maintenance Task

When the team is ready to begin working through the maintenance task selection logic, you double-click

the Tasks node associated with the first failure mode (“Belt conveyor bearing worn or seized due to

improper lubrication”) to open the Task Manager window. Notice that the FEC value for the effect is

displayed under the window’s Ribbon, along with the task selection questions from the RCM logic that

are applicable for effects with “Evident Economic Consequences.”


The team determines that an appropriate task is to lubricate the conveyor bearings on a regular basis. To

indicate this, you change the answer to question 5A to Yes and enter additional comments in the

Explanation field, as shown next.




To define a task, you click the Add Task button.

In the Maintenance Task window, you do the following:

Enter “Lubricate conveyor bearings” in the Task Name field.

Choose Lubrication (LU) from the Task Type drop-down list.

To set the interval, click the drop-down list in the Task Scheduling area and select At certain

intervals. Click Based on the calendar time and then click OK . Two new rows appear in the

table so you can enter the interval.


Enter 2 in the Fixed Interval field.

Choose Week (Wk) from the Unit drop-down list to set the lubrication interval to 2 weeks.

The Maintenance Task window will look like the following picture:





You then close both the Maintenance Task window and the Task Manager window by clicking OK on

each window. The analysis hierarchy looks like the following:




Generating a Report

When you are ready to generate a print-ready report that displays the analysis information, you choose

Home > Reporting > Reports. The Reports window provides a choice of predefined and custom report

forms that can be included in a report document generated in either Microsoft Word or Excel.

You decide that the report should show the following:

Equipment selection details

Functional failure analysis

Failure effect categorization

Maintenance task selection


Assigned maintenance tasks

To build the desired report, you do the following:

Select Conveyor Belt in the Select Items area.






Click the Exclude All button (<<) to remove any existing reports in the Selected Reports area.

Select the five desired report forms from the Available Reports area and move them to the


For example, to include the results of the equipment selection analysis, you select the Risk Discovery

Details (One per Item) report in the Risk Discovery section in the Available Reports area. To move

it to the Selected Reports area, you click the report and then drag it to the desired location in the


After selecting all five reports, the window will look like this:

You click Generate Report and specify the name and location where the report file will be saved. The

report then opens automatically in Microsoft Excel.

RELIASOFT CORPORATION END-USER LICENSE

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Application by ReliaSoft Corporation.

4 SOFTWARE TRANSFERS

4.1 Single User License. You may permanently transfer all of your rights related to a SingleUser License under this Agreement, provided that You retain no copies, You transfer all of the Application (including all component parts, media, printed or electronic materials, anyupgrades and this Agreement) and the transferee agrees to the terms of this Agreement. If the Application is an upgrade, any transfer must include all prior versions of the Application.

Single User License transfers are only allowed between Named Users of the same

organization (i.e., transfers are not allowed across different organizations). The NamedUser transferring the Application must deactivate any and all active installations of the Application before the transferee can Activate the Application. A Single User License maynot be transferred more than two times in a calendar year. This section also applies toSingle User License Rentals.



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4.2 Standard Network, Concurrent Network, Asset-based and Unlimited User Licenses.Standard Network, Concurrent Network, Asset-based and Unlimited User licenses are NOTtransferable across organizations, and licensing rights CANNOT be split or transferredbetween multiple organizations in cases of corporate acquisitions or divestitures, except asallowed in items (a) and (b) of this section (Section 4.2), and with ReliaSoft Corporation’swritten consent.

In the case of Standard and Concurrent Network Licenses, Named User Activations can bedeactivated and replaced by new users on a permanent basis. In other words, replacementof users is allowed to accommodate attrition and reassignment of user responsibilities in theordinary course of doing business. However, replacing users on a daily, weekly, monthly or even quarterly basis and frequently reactivating users that were previously replaced is anindication that the number of Named Users (for Standard Network Licenses) or NamedUser Activations (for Concurrent Network Licenses) obtained by You is not adequate toserve the pool of users intending to Access the Application and is therefore prohibited. EachStandard Network License seat or Concurrent Network Named User Activation can bereassigned to a different Named User no more than two times in a calendar year.

In cases of corporate acquisitions or divestitures: (a) Standard Network and ConcurrentNetwork licenses remain with the organization that originally obtained the licenses, (e.g., if the organization that holds the license is acquired by another entity, the licensing rights willbe transferred to the acquiring entity); (b) Unlimited Site-Wide licenses remain with theoriginal licensing site and therefore pass on to the owner of the specific licensing site aslong as the site continues to exist; (c) Unlimited Division-Wide licenses remain with theorganization that originally obtained the licenses in cases where the Division is beingpartially divested, and are terminated when the Division is fully divested. As an example, ina partial divestiture, the portions of the Division divested will not have access to theDivision-Wide license whereas the portions of the Division that remain will continue to haveaccess to the Division-Wide license; and (d) Unlimited Corporate-Wide licenses remain withthe organization that originally obtained the licenses as long as said organization divested aportion of its business or acquired other organizations, and are terminated in cases where

said organization was acquired by another organization. As an example, in a partialdivestiture, the portions of the corporation divested will not have access to the Corporate-Wide license whereas the portions of the corporation that remain will continue to haveaccess to the Corporate-Wide license. As a further example, an organization with aCorporate-Wide license having acquired other entities (either in part or in whole) willcontinue to have the same licensing rights as before the acquisition and can thereforedeploy the same licensing rights to the newly acquired entities.

This section also applies to Standard Network and Concurrent Network License Rentals.

5 DESCRIPTION OF OTHER RIGHTS, LIMITATIONS AND MISCELLANEOUS

ITEMS5.1 Limitations on Reverse Engineering, Decompilation and Disassembly. You may not

reverse engineer, decompile or disassemble the Application. You shall not provide, discloseor otherwise make available the Application in any form to any person other than your



or otherwise make available the Application, in any form, to any person other than your employees and under your direction and control for purposes specifically related to your permitted use of the Application. You will not: (a) alter, modify or prepare derivative worksof the Application; (b) transmit the Application electronically by any means; or (c) cause or permit the translation, reverse engineering, disassembly, or decompilation of the Application

to determine any design structure, source code, concepts and methodology behind the Application, whether to incorporate it within any product of your own creation, create aderivative work, create any product that is competitive with the Application or other ReliaSoft Corporation products, or for any other purpose.

5.2 Copyright. All title and copyrights to the Application are owned by ReliaSoft Corporation (or its suppliers or licensors). The Application is protected by copyright laws and internationaltreaty provisions. Therefore, You must treat the Application like any other copyrightedmaterial except that You may make one copy of the media solely for backup or archival

purposes.5.3 Proprietary Notices. All title, trademarks, copyrights and intellectual property rights in and

pertaining to the Application (including but not limited to any copies thereof, softwarestructure and organization, source code, images and new releases) are valuable property of ReliaSoft Corporation and are owned or licensed by ReliaSoft Corporation. You may notintentionally remove, alter or destroy any form of copyright and trademark notices,proprietary markings or confidential legends placed upon or contained within the Application, including but not limited to any such notices contained in physical and/or

electronic media or documentation, in the Application interface boxes, or in any of theruntime resources, code or other embodiments originally contained in or dynamically or otherwise created by the Application.

5.4 Use of ReliaSoft Corporation’s Marks. You may not use the name, logos, trade names or trademarks of ReliaSoft Corporation or any of its affiliates in any manner including, withoutlimitation, in your advertising, promotional literature or any other material, whether inwritten, electronic, or other form distributed to any third party, except in the form provided byReliaSoft Corporation and then solely for the purposes of identifying your use of the

ReliaSoft Corporation Application.5.5 Verification. You will provide, on ReliaSoft Corporation’s reasonable written request,

written verification that the Application is being used according to the terms of this Agreement. Upon thirty days prior written notice, if ReliaSoft Corporation has reasonablegrounds to believe that this Agreement has been breached, ReliaSoft may audit your use of the Application provided such audit is: (a) limited to records relating solely to the Applicationnecessary to verify compliance with the terms of this Agreement; (b) performed by areputable independent third party auditor acceptable to You (acting reasonably); (c) the

third party auditor shall comply with your standard security policies; (d) the third party

auditor shall execute your standard protective non-disclosure agreement; and (d) the cost of any requested audit will be solely borne by ReliaSoft Corporation if no breach is found as aresult of the audit or will be solely borne by You if a breach is found. Such audit shall occur no more than once every twelve months and shall not unreasonably interfere with your normal business operations.



5.6 Modification. ReliaSoft Corporation reserves the right to modify or enhance the Applicationwithout obligation to notify You of such changes or to furnish them to You, unless otherwiseagreed upon with a separate agreement (such as an annual maintenance agreement).

5.7 Copying. You may not, under any circumstances, copy the Application, in whole or in part,

except as expressly provided under the Copyright section above.5.8 Separation of Components. The Application is licensed as a single product. Its

component parts may not be separated for use on more than one computer.

5.9 Rental or Other Exploitation. You may not publish, sub-license, re-license, assign, sell,distribute, license, transfer, rent, lease or lend the Application to any party, except transfer the Application as expressly provided under the Transfer section above. If you received anyrevenues from the unlawful distribution of the Application, such revenues will be forfeited toReliaSoft Corporation.

5.10 Fees. You will pay ReliaSoft Corporation all fees or other amounts due under this Agreement, plus any and all applicable taxes, within the payment term due date specifiedon the respective invoice. In the event that the respective invoice is not paid on time, or atall, ReliaSoft Corporation reserves the right to terminate this Agreement and revoke thecorresponding licenses issued to You within the scope of this Agreement.

5.11 Termination. Without prejudice to any other rights, ReliaSoft Corporation may terminatethis Agreement if You fail to comply with the terms and conditions of this Agreement andsuch breach is not cured within thirty days of notice of such breach. In such event, You

must destroy all copies of the Application and all of its component parts. Additionally, Youmay be held liable for any damage or loss of profit caused to ReliaSoft Corporation arisingfrom unauthorized use or duplication of this Application.

5.12 Supplemental Licenses. If, after the effective date of this Agreement, You subsequentlypurchase additional licenses of the Application, these supplemental licenses will beincluded under this Agreement.

5.13 Press Releases. As part of this Agreement, You acknowledge that ReliaSoft Corporationmay make reference to You as a customer of ReliaSoft Corporation in press releases,advertising and promotional materials, and You consent to any such reference. ReliaSoftCorporation will NOT disclose any further details beyond referring to You as a customer without prior written consent, not to be unreasonably withheld.

5.14 Relationship. You and ReliaSoft Corporation are independent contractors and neither is anagent, joint venture partner, partner or employee of the other, and ReliaSoft Corporation willnot be obligated by any agreements or representations made by You to any person, nor with respect to any other action by You, nor will ReliaSoft Corporation be obligated for any

damages to any person, whether caused by your actions, failure to act, negligence or willfulconduct.

5.15 Upgrades. If the Application is an upgrade from another product, whether from ReliaSoftCorporation or another supplier, You may use or transfer the Application only in conjunctionwith that upgraded product, unless You destroy the upgraded product. If the Application is



an upgrade of a ReliaSoft Corporation product, You may use the upgraded product only inaccordance with this Agreement. If the Application is an upgrade of a component of apackage of software programs that You licensed as a single product, the Application maybe used and transferred only as part of that single product package and may not beseparated for use on more than one computer.

5.16 U.S. Government Restricted Rights. The Application was developed at private expense.No portion of the Application was developed with government funds and the Application is atrade secret of ReliaSoft Corporation for all purposes of the Freedom of Information Act.The Application and documentation are provided with RESTRICTED RIGHTS. Use,duplication or disclosure by the Government is subject to restrictions as set forth insubparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause atDFARS 252.227-7013 (or its successor) or subparagraphs (c)(1) and (2) of the CommercialComputer Software Restricted Rights at 48 CFR 52.227-19 (or its successor), asapplicable. Manufacturer is ReliaSoft Corporation, 1450 S. Eastside Loop, Tucson, Arizona85710, USA.

5.17 Limited Warranty. ReliaSoft Corporation warrants that: (a) the Application will performsubstantially in accordance with the accompanying written materials, and on machinesmeeting the published minimum requirements, for a period of sixty (60) days from the dateof receipt; and (b) any media on which the Application is furnished will be free from defectsfor a period of sixty (60) days from the date of receipt. Some states and jurisdictions do notallow limitations on duration of an implied warranty, so the above limitation may not apply toYou; in such states and jurisdictions the liability of ReliaSoft Corporation shall be limited tothe minimum extent permitted by law. To the extent allowed by applicable law, impliedwarranties on the Application and media, if any, are limited to sixty (60) days; and (c) at thetime of installation, the Application will be free from any mechanism, feature or any other codes or instructions that: (i) cause the Application to remotely transmit information toReliaSoft or any third party, except to communicate with one of ReliaSoft’s servers tofacilitate specific functions of the Application (such as to communicate with the ReliaSoftLicense Server, access the online help files, etc.); or (ii) may be used to permit Access to,

or use of, the Application or computer system on which the Application is loaded, or towhich the Application is linked, by ReliaSoft or any third party.

5.18 Customer Remedies. ReliaSoft Corporation's and its suppliers' or licensors’ entire liabilityand Your exclusive remedy shall be, at ReliaSoft Corporation's option, either (a) return of the fee paid for the Application, or (b) repair or replacement of the Application or media thatdoes not meet ReliaSoft Corporation's Limited Warranty and which is returned to ReliaSoftCorporation with a copy of your receipt or invoice. Any replacement Application or mediawill be warranted for the remainder of the original warranty period or thirty (30) days,

whichever is longer. None of these remedies nor any product support services offered byReliaSoft Corporation are available without a valid License Certificate issued by ReliaSoftCorporation.

5.19 Warranty Exclusions. The Limited Warranty is void if the damage or defect has resultedfrom accident, abuse or misapplication. Any modification of the Application by any personth th R li S ft C ti h ll id thi t A i l ti f th



other than ReliaSoft Corporation shall void this warranty. Any manipulation of the Application’s data storage infrastructure or direct storage of data into the Application’s datastorage from outside the Application by any person other than ReliaSoft Corporation or ReliaSoft Corporation’s authorized representative shall void this warranty. The warranties inthis section extend only to You and are contingent upon proper use of the Application. Thewarranties will not apply to any failure caused by (a) accident, (b) unusual physical,electrical or electro-magnetic stress, (c) negligence, (d) misuse, (e) failure of electricalpower, air conditioning or humidity control, (f) use of the Application with any equipment or software not reflected in ReliaSoft Corporation’s specifications, (g) installation, alteration or repair of the Application by anyone other than ReliaSoft Corporation or ReliaSoftCorporation’s authorized representative, or (h) or installation on equipment on which theoriginal identification marks have been removed or altered.

5.20 No Other Warranties. No oral or written information or advice given by ReliaSoftCorporation, its suppliers, dealers, distributors or agents shall create a warranty or in anyway increase the scope of the Limited Warranty, and You may not rely on any suchinformation or advice as a warranty.

5.21 Use of Results Provided By the Application Disclaimer . You understand that the resultsprovided by the Application cannot replace judgment required for important decisions. Useof the results provided is done completely at your own risk. ReliaSoft Corporation does notwarrant that the functions of this Application will meet your requirements or be error free.You assume all risk of the use, quality and performance of the Application, and You areadvised to use your own discretion and judgment regarding the use of the Application.

5.22 RELIASOFT CORPORATION, ON BEHALF OF ITSELF AND ITS LICENSORS,DISCLAIMS ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING,BUT NOT LIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE, WITH REGARD TO THE APPLICATION. IN NO EVENTSHALL RELIASOFT CORPORATION OR ITS SUPPLIERS OR LICENSORS BE LIABLEFOR ANY SPECIAL, INCIDENTAL, INDIRECT, OR CONSEQUENTIAL DAMAGESWHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OFBUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATIONOR ANY OTHER PECUNIARY LOSS) ARISING OUT OF THE USE OF OR INABILITY TOUSE THE APPLICATION, EVEN IF RELIASOFT CORPORATION HAS BEEN ADVISEDOF THE POSSIBILITY OF SUCH DAMAGES. USE OF THIS APPLICATION IS DONECOMPLETELY AT YOUR OWN RISK, INCLUDING THE USE OF RESULTS PROVIDEDBY THIS APPLICATION. RELIASOFT CORPORATION’S LIABILITY HEREUNDERSHALL BE LIMITED TO PHYSICAL DAMAGE DIRECTLY CAUSED BY THE SOLENEGLIGENCE OF RELIASOFT CORPORATION AND SHALL NOT EXCEED THE PRICE

PAID FOR THE SOFTWARE PRODUCT. NOTWITHSTANDING ANYTHING HEREIN TOTHE CONTRARY, THE FOREGOING DISCLAIMER AND LIMITATION OF LIABLITYSHALL NOT APPLY TO RELIASOFT CORPORATION’S OBLIGATIONS UNDER ANYCLAIM OF INFRINGEMENT AS DESCRIBED IN SECTION 5.28 OF THIS AGREEMENT.

5.23 Venue. Venue for any proceedings arising out of or relating to this Agreement shall be inTucson Pima County Arizona The parties disclaim the application of the United Nations



Tucson, Pima County, Arizona. The parties disclaim the application of the United NationsConvention on Contracts for the International Sale of Goods. This Agreement is governedby the laws of the State of Arizona, USA, without reference to conflict to law principles.Each party to this Agreement submits to the exclusive jurisdiction of the state and federalcourts in the State of Arizona for the purpose of resolving any disputes arising under or relating to this Agreement. Each party waives any jurisdictional, venue or inconvenientforum objections to such courts.

5.24 Legal Expenses. If legal action is taken by either party to enforce this Agreement, all costsand expenses (including reasonable attorney fees) incurred by the prevailing party inexercising any of its rights or remedies or in enforcing any of the terms, conditions, or provisions of this Agreement will be paid by the other party.

5.25 Force Majeure. ReliaSoft Corporation will not be responsible for delays or failures in its

performance due, in whole or in part, to any cause beyond its reasonable control.5.26 Export Control. Regardless of any disclosure made by You to ReliaSoft Corporation of an

ultimate destination of the Application, You will not export, either directly or indirectly any Application without first obtaining all licenses required, from the U.S. Department of Commerce or any other agency or department of the United States Government, andcomplying with the applicable laws. Neither the Application nor any direct product thereof may be exported, directly or indirectly, in violation of applicable export laws, or may be usedfor any purpose prohibited by these laws including, without limitation, nuclear, chemical or

biological weapons proliferation. ReliaSoft Corporation will provide You with all reasonableinformation requested by You in connection to exporting the Application, including providingYou with the U.S. Export Controls Classification Number (ECCN) for the Application.

5.27 Waiver . The waiver by either party of any breach of this Agreement shall be in writing andshall not constitute a waiver of any other or subsequent breach. No waiver of any of theprovisions of this Agreement will be deemed, or will constitute, a waiver of any other provision, whether or not similar, nor will any waiver constitute a continuing waiver. Thefailure by a party to enforce any provision of this Agreement will not be deemed a waiver of

future enforcement of that or any other provision.5.28 Indemnification. You will indemnify and hold ReliaSoft Corporation harmless against any

and all claims, damages, losses, costs or other expenses (including reasonable attorneyfees) that arise directly or indirectly from your breach of this Agreement. ReliaSoftCorporation shall defend, indemnify and hold harmless, at its own expense, You and your assigns, successors, directors, officers and employees (each an “Indemnified Party”)against any and all claims incurred by or made against an Indemnified Party by a third partyin connection with a claim, suit or action which is based on an allegation that the Application

when used by You as authorized under this Agreement, misappropriates or infringes any

third party patent, copyright, trade secret or other intellectual property right (each, a “Claim”)provided that ReliaSoft Corporation shall have received from the Indemnified Party: (i)notice of such Claim as soon as possible after You receive notice of the Claim; given that afailure to provide notice shall only relieve ReliaSoft Corporation of its indemnity obligation tothe extent ReliaSoft Corporation was prejudiced by such failure; (ii) the exclusive right tocontrol and direct the investigation, defense or settlement of such claim; and (iii) all



g , ; ( )reasonable necessary cooperation by You. If your use of any of the Application is, or inReliaSoft Corporation’s opinion is likely to be, enjoined due to a Claim, ReliaSoftCorporation may, at its sole discretion: (a) modify the Application so that it becomes non-infringing, provided such modifications result in software with substantially similar

functionality and performance; (b) procure for You the right to continue using the Applicationunder substantially the same terms and conditions as provided for hereunder; or (c) if (a)and (b) are commercially impracticable, terminate the Agreement and refund to You thelicense fee paid by You for the Application which is the subject of the Claim as reduced toreflect a three-year straight-line depreciation from the applicable license purchase date. Theforegoing indemnification obligation of ReliaSoft Corporation shall not apply: (1) if the Application is modified by any party other than ReliaSoft Corporation and such modificationwas not authorized in writing by ReliaSoft Corporation, but solely to the extent the alleged

infringement is caused by such modification; or (2) to any release of the Application other than the most current release, provided that: (I) the most current release was either madeavailable at no cost to You and (II) You had a commercially reasonable period of time (notto exceed 60 days) after availability of the current release to implement the current releaseso as to avoid the infringement claim. This section (Section 5.28) sets forth ReliaSoftCorporation’s sole liability and your sole and exclusive remedy with respect to any claim of infringement.

5.29 Equitable Relief. You acknowledge and agree that, due to the unique nature of the

Application, there can be no adequate remedy at law for any breach of your obligationsunder this Agreement, that any such breach may allow You or third parties to unfairlycompete with ReliaSoft Corporation resulting in irreparable harm and therefore that, uponany such breach or threat thereof, ReliaSoft Corporation shall be entitled to injunctive andother appropriate equitable relief in addition to whatever remedies it may have at law.

5.30 Entire Agreement; Amendments. This Agreement is the complete and exclusivestatement of the agreement between the parties and supersedes all prior agreements andcommunications with respect to the subject matter, and there are no oral representations,

understandings or agreements that are not fully expressed herein. Any terms appearing onany order or other form used by You which modify or conflict with the terms and conditionsset forth herein are expressly rejected. Except for the purpose of negating impliedwarranties, no course of prior dealings between the parties and no usage of the trade shallbe relevant to supplement or explain any term used in this Agreement. No ReliaSoftCorporation employee other than an officer of ReliaSoft Corporation (Vice President andabove) shall have any actual or apparent authority to modify the terms of this Agreement inany way. All amendments shall be in writing and signed by the authorized representative of

ReliaSoft Corporation.

5.31 Severability. If any one or more of the provisions of this Agreement shall for any reason beheld to be invalid, illegal or unenforceable in any respect, any such provision shall beseverable from this Agreement, in which event this Agreement shall be construed as if suchprovision had never been contained herein.

5.32 Electronic Signatures. ReliaSoft Corporation and You agree that this Agreement may beexecuted electronically and that electronic copies of this Agreement shall be binding upon



executed electronically and that electronic copies of this Agreement shall be binding uponthe parties to the same extent as manually-executed copies.

