Benchmark your Reliability-Centered Maintenance process against SAE JA1011/JA1012 international standards. Is your RCM really RCM? Find out in 20 minutes.
Important Disclaimer: This assessment is a self-evaluation tool for educational and awareness purposes. It does NOT constitute formal SAE JA1011 certification or third-party audit verification. Organizations seeking formal compliance verification should engage qualified RCM auditors.
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JA1011 §5.1 — Functions and Performance Standards: The RCM process must define the operating context of the asset/system and identify all functions with measurable performance standards.
JA1011 §5.1.1 — Operating context includes: duty cycle, environment, quality standards, safety requirements
JA1011 §5.1.2 — Example: 'Transfer water at 100 m³/hr at 3 bar pressure'
JA1011 §5.1.3 — Secondary functions often outnumber primary functions
JA1011 §5.1.4 — Example: 'Relieve overpressure to protect vessel from rupture, available 99.9% of time'
JA1011 §5.1.2 — Good: 'Pump 100 m³/hr' / Poor: 'Pump fluid'
JA1011 §5.1.1 — Define what's IN and OUT of scope
JA1012 §3 — Cross-functional input ensures completeness
JA1011 §5.2 — Functional Failures: All reasonably likely failure states for each function must be identified, including total and partial loss of function.
JA1011 §5.2.1 — Partial loss example: 'Pump delivers only 60 m³/hr instead of 100'
JA1011 §5.2.1 — 'User' = the organization, not just operators
JA1011 §5.2.2 — Over-performance can be a failure (e.g., cooling system making product too cold)
JA1011 §5.2.1 — Hidden failures of protective devices are critical
JA1011 §5.2.1 — Traceability is essential for audit
JA1011 §5.3 — Failure Modes: All failure modes reasonably likely to cause each functional failure must be identified at a level of detail that allows selection of an appropriate maintenance policy.
JA1011 §5.3.1 — 'Reasonably likely' = has happened OR could happen based on experience
JA1011 §5.3.2 — Poor: 'Pump fails' / Good: 'Impeller erodes due to cavitation'
JA1011 §5.3.2 — Include WHY it fails: wear, corrosion, fatigue, human error
JA1011 §5.3.1 — Use maintenance history, industry databases
JA1011 §5.3.1 — Don't assume current PM is optimal — analyze anyway
JA1012 §7.3 — This determines if scheduled replacement is effective
JA1011 §5.3.2 — Helps identify systemic issues
JA1012 §6.3 — Avoid over-analyzing some assets while under-analyzing others
JA1011 §5.4 — Failure Effects: The effects of each failure mode must describe what happens when it occurs, assuming no proactive maintenance is done.
JA1011 §5.4.1 — Describe the 'unmitigated' scenario
JA1011 §5.4.2 — Alarms, visual signs, performance changes
JA1011 §5.4.2 — Be specific: not 'risk of injury' but 'risk of burn injury from steam release'
JA1011 §5.4.2 — 'Production loss of X units' or 'Downtime of Y hours'
JA1011 §5.4.2 — Helps with spare parts and resource planning
JA1011 §5.4.1 — Both are needed for complete picture
JA1011 §5.5 — Failure Consequences — THE DECISION DRIVER: Consequences determine the maintenance strategy. They must be categorized into Hidden, Safety, Environmental, Operational, and Non-operational.
JA1011 §5.5.1 — All 5 required! Non-operational = only repair cost, no production impact
JA1011 §5.5.2 — Hidden failures expose the organization to MULTIPLE FAILURE risk
JA1011 §5.5.2 — Example: 'If backup fails AND primary fails, then total loss of cooling'
JA1011 §5.5.1 — This drives DIFFERENT task selection criteria
JA1011 §5.5.1 — Baseline = no maintenance intervention
JA1011 §5.5.1 — Wrong: 'We do PM, so it's not critical' / Right: 'It's critical, so we need PM'
JA1011 §5.5.3 — License to operate, legal liability
JA1011 §5.6 — Proactive Tasks: A structured decision logic must be used to select technically feasible and worth-doing maintenance tasks based on consequence category.
JA1011 §5.6.1 — The decision logic is the HEART of RCM
JA1011 §5.6.2 — Feasible if: P-F interval is long enough AND failure is detectable
JA1011 §5.6.3 — Only feasible for age-related failure modes with defined wear-out
JA1011 §5.6.4 — Only feasible for age-related failures; often mandated for safety items
JA1012 §9.2 — Formula: Task interval ≤ P-F interval ÷ 2
JA1011 §5.6.1 — Different criteria for different consequence categories
JA1011 §5.6.1 — OEM may be conservative; use YOUR operating context
JA1011 §5.6.2 — Failure-finding interval depends on required availability
JA1011 §5.7 — Default Actions — Completing the Analysis: When no proactive task is feasible and worth doing, default actions must be assigned. Every failure mode must receive a decision.
JA1011 §5.7.1 — Every failure mode gets a decision — no gaps
JA1011 §5.7.2 — Test the protective device at defined intervals
JA1012 §8.2 — FFI formula considers acceptable multiple failure probability
JA1011 §5.7.3 — No 'accept the risk' option for safety — must redesign
JA1011 §5.7.4 — RTF is a valid strategy when consequences are purely economic
JA1011 §5.7.1 — Audit trail from analysis to work order
JA1012 — Implementation Requirements: RCM must be performed by cross-functional teams with competent facilitation. Analyses must be kept current as a living program.
JA1012 §12.1 — Minimum: operator, maintainer, technical specialist, facilitator
JA1012 §12.2 — Training alone is not enough — verify competence
JA1012 §11.1 — RCM is a LIVING program, not a one-time project
JA1012 §12.3 — Management sign-off ensures commitment
JA1012 §11.2 — Actual failure data improves analysis accuracy
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Disclaimer: This assessment is a self-evaluation tool for educational and awareness purposes. It does NOT constitute formal SAE JA1011 certification or third-party audit verification.
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