A complete worked RCM analysis on a representative system
Synthetic example using illustrative data. Not from any client or employer. Boiler feed pump train (BFP-2), documented end to end for instruction.
Most RCM material teaches the seven questions in SAE JA1011 and stops. It does not show the scoping argument in week one, the FMEA session that stalls, the modes people argue about, or what a finished task list looks like on the page. This example walks a representative boiler feed pump train — labeled BFP-2 in the worksheets — from system selection through functions, failure modes, consequences, and task selection.
Use it as a pattern, not as a copy-and-paste analysis for your pump. Duties, fluids, spares, and protective functions differ. Adjust every mode. The downloadable file carries the same synthetic-data label as this page.
What the file contains.
- System selection and scopingWhy this representative system, where the boundaries sit, and what “failure” means for it. The step most analyses rush and regret.
- Functions and functional failuresWhat the system must do, and every way it can fail to do it, stated in terms operators recognize.
- FMEA sessionsFailure modes with the people who would run and wrench on the equipment in a real plant. Notes on what kept sessions moving, and what stalled them.
- Consequences and task selectionHidden, safety, outage, and non-outage consequences, and which tasks are worth doing for each mode, following the logic of SAE JA1011.
- The task listThe finished example list, and a short leadership brief format. This is an instructional output, not a record of a funded or implemented program.
Request the PDF and working files with a work email. The same material is described on this page so you can decide whether you want the file. Related tools: the RCM Analysis Workbook, the Facilitator’s Kit, and RCM facilitation if you want this done on your system.