The project applied a tailored RCM analysis in full compliance with the globally recognized standard SAE JA1011: Evaluation Criteria for Reliability-Centred Maintenance (RCM) Processes, targeting a critical system with significant reputational risk implications. The goal was to deliver a streamlined, sustainable maintenance solution, featuring clear, precise instructions linked to the correct spares. This approach optimised workforce efficiency, minimised administrative overheads, and ensured compliance.

To develop a streamlined, sustainable maintenance strategy, we conducted a system-level Failure Modes, Effects, and Criticality Analysis (FMECA) to assess potential failure modes, their likelihood, and criticality based on operational impact, cost, safety, and reputational risk. Using these insights, we populated both planned and unplanned work orders in AMOS, ensuring seamless integration with operational and upkeep maintenance processes. Task instructions and spare parts details were provided in an AMOS-compatible format, aligning planned spares with the AMOS scheduler and structuring allocations by financial year to support demand planning. To further enhance efficiency, an advanced algorithm was implemented to calculate optimal stockholding levels for unplanned spares, factoring in failure probability, severity, and operational requirements. Finally, workload estimates were generated to aid in resource planning, providing valuable comparisons against the OEM maintenance baseline.