Reliability-Centered Maintenance (RCM) Checklist
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Asset Identification & Scope Definition
Defining the assets included in the RCM analysis and establishing clear boundaries.
Asset Name/Designation
Asset ID / Serial Number
Brief Description of Asset and its Purpose in Manufacturing
Asset Location within the Manufacturing Facility
Criticality Ranking (High, Medium, Low)
Date of Last Major Overhaul/Replacement
List of Connected Systems / Interdependencies
Asset Status (Operational, Out-of-Service, Decommissioned)
Functional Analysis
Understanding the intended functions of the equipment and their importance to the manufacturing process.
Describe the primary function(s) of the equipment in the manufacturing process.
Describe the secondary or supporting functions of the equipment.
What is the criticality of this equipment to production?
Estimated Production Output (Units/Hour) if equipment is functioning normally.
List any dependencies the equipment has on other systems or processes.
Is the equipment part of a critical safety system?
Describe any regulatory or compliance requirements related to the equipment’s function.
Failure Mode Identification
Identifying potential ways the equipment can fail and impact its function.
Describe the Potential Failure Mode
Failure Mode Category (e.g., Mechanical, Electrical, Hydraulic)
Estimated Frequency of Failure Mode (per year)
Initial Severity of Failure Mode (Impact on Process)
Describe any visible indicators or warning signs of this failure mode
Which components are directly involved in this failure mode?
Failure Effect Analysis
Determining the consequences of each failure mode on the overall manufacturing process.
Describe the Impact on Production Output
Describe the Impact on Product Quality
Describe the Impact on Safety (Personnel and Environment)
Describe the Impact on Other Equipment or Processes
Estimated Downtime (hours) due to this failure mode
Estimated Cost of Production Loss (USD) due to this failure mode
Estimated Cost of Repair/Replacement (USD)
Severity Ranking (1-Critical, 5-Minor)
Failure Cause Identification
Identifying the root causes and contributing factors for each failure mode.
Describe the primary cause of the failure mode.
Select all contributing factors to the failure (e.g., environment, operator error, material defect).
Estimated Frequency of Root Cause Occurrence (e.g., times per year)
Describe any historical data or past incidents that support the identified root cause.
Severity of Root Cause (Impact on overall system failure)
Upload any supporting documentation (e.g., maintenance logs, inspection reports, test results).
Describe the current level of control or mitigation for this root cause (if any).
Maintenance Task Selection
Selecting appropriate maintenance tasks to prevent or mitigate failures, based on risk assessment.
Primary Maintenance Task Type?
Task Frequency (if Time-Based)
Task Description & Procedure
Condition Monitoring Method (if Condition-Based)
Condition Threshold Limit
Initial Task Implementation Date
Skills Required for Task Completion
Rationale for Task Selection
Task Priority Level
Maintenance Task Implementation & Scheduling
Implementing and scheduling the selected maintenance tasks into the maintenance plan.
Maintenance Task Priority (Based on RCM Analysis)
Scheduled Task Start Date
Scheduled Task Start Time
Estimated Task Duration (Hours)
Detailed Task Instructions & Safety Precautions
Required Tools & Equipment
Maintenance Skill Level Required
Attach Relevant Documentation (e.g., diagrams, procedures)
RCM Documentation & Review
Documenting the RCM process, decisions, and findings, and establishing a review schedule.
RCM Plan Narrative Summary
Date of Initial RCM Analysis
Date of Last RCM Review
Review Frequency (e.g., every 12 months)
Review Type
Summary of Review Findings & Actions
Areas of Review Considered (check all that apply)
Supporting Documentation (e.g., updated FMEA)
Reviewer Name
Reviewer Signature
Training and Communication
Ensuring maintenance personnel are properly trained on the RCM plan and the reasoning behind maintenance tasks.
Training Objectives Description
Topics Covered in RCM Training (Select All That Apply)
Number of Personnel Trained (Initial)
Date of Last RCM Training Session
Summary of Key Training Messages & Communication Strategy
Communication Method for RCM Updates/Changes
Training Materials Upload (e.g., Presentations, Guides)
Continuous Improvement & Monitoring
Monitoring the effectiveness of the RCM plan and making adjustments as needed based on performance data.
Mean Time Between Failures (MTBF) Trend
Mean Time To Repair (MTTR) Trend
Failure Rate (Failures per Unit Time)
Deviation from Planned Maintenance Task Completion?
Observations and Notes on Equipment Performance
Date of Last RCM Review
Areas for Potential Improvement Identified?
Summary of RCM Plan Effectiveness Discussion
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