Workbook

Reliability-Centered Maintenance (RCM) Workbook

Interactive workbook to run RCM analysis by asset, capture failure modes, evaluate consequences and detectability, select maintenance tasks, estimate intervals and costs, and save structured RCM entries for later review or export.

Interactive Tool

RCM Workbook - Structured Entry

Use this form to capture one asset-level RCM analysis entry. Record the asset identity, its critical functions, observed or potential failure modes, consequence assessment, recommended maintenance tasks, intervals, spare-part needs, and brief cost-benefit notes. Save each failure-mode analysis as a separate submission (you may submit multiple times for the same asset to cover multiple failure modes).

Helpful formulas: Risk Priority Number (RPN) = Severity × Probability × Detectability. Use RPN to help prioritize actions, but always include business context before changing strategy.

Enter the unique asset identifier or descriptive name (e.g., Pump-101).
Choose the best matching asset class.
Where the asset operates (e.g., Line A - Cell 3, Plant 2).
Briefly list what the asset must do to deliver value (one function per line).
Describe the observed or potential failure mode. If multiple failure modes exist for this asset, submit this form once per failure mode or list each on a separate line and treat each as a separate analysis result.
Select the main type of consequence if this failure occurs.
Rate the severity of the consequence if the failure occurs (1 = minor, 5 = catastrophic).
1.0 10.0
Rate how likely the failure is to occur in the assessment period (1 = rare, 5 = frequent).
1.0 10.0
Rate detectability where 1 = easily detected before consequence and 5 = very hard to detect until failure manifests. Higher values increase RPN.
1.0 10.0
Optional: calculate Severity × Probability × Detectability and enter result to aid prioritization.
Choose the type of task most appropriate for this failure mode.
Describe the task, steps, and clear acceptance criteria (what indicates the asset is fit-for-service). Include condition thresholds if CBM is chosen.
Enter the numeric interval (e.g., 30). Leave blank for run-to-failure or condition-based tasks without a fixed interval.
Choose the unit for the interval value.
Estimate the labor time required for the task (hours).
Material + labor estimated cost for one execution of the task.
Expected asset downtime caused by performing this task.
Select Yes if a spare or consumable is required to complete the task.
If a spare is required, list SKU, description, recommended stock quantity, and supplier lead time. Leave blank if not required.
Brief notes on expected benefits (reduced downtime, safety improvement, quality gains) and why the task is justified (or not). Include payback or break-even comments if available.
Person, role, or team responsible for implementing and reviewing this action.
Date to re-assess the failure mode and task effectiveness. Use ISO format.
List URLs or document IDs for photos, vibration spectra, past failure reports, drawings, or SOPs.
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