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Reliability Centred Maintenance Consulting

Reliability Centred Maintenance that ends in a defensible maintenance program, not a binder

HolisticAM facilitates SAE JA1011 RCM studies that finish as CMMS-loaded maintenance programs: functions, failure modes, consequences, task selection, frequencies, spares and master data, built by engineers who maintained the assets themselves.

For ANSTO's Australian Synchrotron we have delivered eight RCM and CHAZOP studies across six new beam lines, with five reports contributing to ARPANSA regulatory submissions.
Scope an RCM study
Train your team in RCM
✓SAE JA1011 aligned studies
✓Sole ANZ ReliaSoft distributor (RCM++)
✓Facilitators from BHP, Rio Tinto, Alcoa and MMG operations
The capability test

Most RCM studies never change a single work order

Ask any RCM provider two questions: who decides which assets deserve the analysis, and who loads the result into your CMMS. If the answers are "all of them" and "your team, later", you are buying a binder. Analysing every asset burns the budget on equipment whose failure barely matters, and an unloaded analysis changes nothing on the tools.

HolisticAM runs criticality first, so RCM effort lands only where the consequence of failure justifies it. Then we carry each failure mode through the seven questions to a task, a frequency, a trade and the master data your planners can schedule. The study is finished when the program is in your CMMS and your team can defend every line of it, including the failure modes where the defensible answer is deliberate run-to-failure.

New to the method? Read the plain-English guide: What is Reliability Centred Maintenance? For the analysis walkthrough, see the step-by-step RCM analysis guide.

What it covers

From criticality shortlist to loaded program

✓

Asset criticality assessment

Tiering your register by consequence of failure, so the analytical spend goes to the assets that can hurt you and not the ones that cannot.

✓

Facilitated RCM studies

Cross-functional workshops through the seven SAE JA1011 questions, onsite or remote. Operators and trades in the room, because the failure knowledge lives with them.

✓

Consequence-driven task selection

Hidden, safety, operational or non-operational: the consequence category picks the task. Condition-based, restoration, discard, failure-finding, or run-to-failure written down and owned.

✓

Program build and CMMS master data

Tasks, frequencies, trades and spares inputs delivered load-ready for your CMMS or ERP. We build most often for SAP and Pronto.

✓

ReliaSoft RCM++

As sole ANZ ReliaSoft distributor we run and supply RCM++, with simulation to compare strategies on cost and availability and to estimate optimum replacement intervals.

✓

RCM training and handover

The three-day RCM Foundations course and side-by-side mentoring, so the program stays alive after we leave.

RCM in numbers

One programme, delivered inside a nuclear regulator's gaze

8
RCM and CHAZOP studies delivered for ANSTO's Australian Synchrotron
6
New beam lines analysed under the Bright expansion project
5
Reports contributing to ARPANSA regulatory submissions
30+
ANSTO staff given practical exposure to RCM and CHAZOP methods

All four numbers come from a single engagement: ANSTO's Australian Synchrotron, where our RCM and CHAZOP programme has run remotely in ReliaSoft RCM++ since 2020, keeping the Bright expansion's regulatory submissions on schedule through the pandemic. These are delivery-scale figures, stated as such: studies, reports and people trained, not availability claims.

Proof

Delivered on regulated plant and working fleets

ANSTO — Australian Synchrotron

Eight RCM and CHAZOP studies across six new beam lines under the Bright expansion, facilitated remotely in ReliaSoft RCM++, with five reports contributing to ARPANSA regulatory submissions and 30+ ANSTO staff given practical method exposure.

Read the case study

P&H 4100XPC shovels — open-cut coal

Consequence-driven strategy work on an electric rope shovel fleet: downtime analysis, Weibull life data analysis and FMECA review, delivered as a data-driven strategy with customised service sheets and SAP master data. Corrective maintenance fell from 56% to 37% of total maintenance in six months, against a 44:56 planned-to-corrective baseline.

Read the case study

Komatsu 930E haul trucks — fleet review

Fleet-wide maintenance review across multiple Australian open-cut mines: Weibull life data analysis, FMECA-based strategy update, service-day execution and MTTR recommendations. The published case study reports 112 additional available hours per truck over six months, with MTBF held above 90 hours.

Read the case study

Newcrest Cadia — RCM capability building

Bespoke training and mentoring for site reliability engineers covering reliability fundamentals, life data analysis, RBD modelling and RCM, with each participant working in ReliaSoft RAM Suite.

Read the case study

“The professional approach and product knowledge ensured we achieved the best outcome for the business. We really appreciate the effort and look forward to continuing this relationship with HolisticAM.”Maintenance Manager, open-cut coal mine (P&H 4100XPC programme)
“HolisticAM has been pivotal in transforming how we undertake maintenance on our assets. Their product knowledge, professionalism and their site experience sets them apart.”Engineering Manager, mining company (Komatsu 930E programme)
Credentials

The bench behind the studies

✓SAE JA1011 — every study answers the standard's seven questions
✓Sole ANZ ReliaSoft distributor — RCM++, XFMEA, Weibull++, BlockSim
✓ISO 55001 — strategies built to sit inside an aligned framework
✓Leadership from BHP, Rio Tinto, Alcoa and MMG — operators, not theorists
✓MD: Master of Maintenance & Reliability — chaired the Victorian Asset Management Council
How an engagement starts

A scoped study, not an open-ended analysis

1

Criticality shortlist

A fixed-scope pass over your asset register and failure history. You get a bounded study plan: which systems, which teams, how many sessions, before you commit to any of it.

2

Facilitated RCM study

The seven questions worked through on your assets with a cross-functional room. Your people carry the operating knowledge; we keep the analysis rigorous and on schedule.

3

Program, loaded and assured

Tasks, frequencies, spares inputs and master data delivered CMMS-ready, with training and a review cycle so the program lives past the study.

Questions

Reliability Centred Maintenance, answered

What does an RCM consultant actually deliver?
A maintenance program justified failure mode by failure mode: task lists with frequencies and trades, spares recommendations, and CMMS-ready master data, plus the documented analysis behind every decision. The deliverable is a loaded, defensible program, not a report.
Do we need RCM or FMECA?
FMECA identifies failure modes, their effects and their criticality, and ends in a ranked risk register. RCM carries those failure modes further: it categorises the consequence of each one and selects the maintenance task and frequency that consequence justifies. If you need to know what your risks are, start with a FMECA; if you need to know what to do about them, you need RCM, and an existing FMECA gives the study a head start. The distinction is covered in our RCM guide.
Is RCM worth running on every asset?
No, and providers who say otherwise are selling workshop hours. Full RCM belongs on the assets where the consequence of failure justifies the analytical investment. That is why every engagement starts with a criticality assessment: it decides where RCM pays and where a lighter method is the honest answer.
Can RCM studies run remotely?
Yes. The ANSTO Synchrotron programme has run eight RCM and CHAZOP studies remotely in ReliaSoft RCM++ since 2020, without interrupting the regulatory submission schedule it supports.
What software do you use?
ReliaSoft RCM++, which supports the major published RCM standards, simulates strategy options on cost and availability, and estimates optimum replacement intervals. We are the sole ReliaSoft distributor for Australia and New Zealand. The method itself is tool-agnostic: where your site already runs another platform, or wants the analysis in a structured worksheet, the decision logic transfers.
How long does an RCM study take?
It depends on system complexity and how many failure modes the criticality shortlist puts in scope. The scoping step exists to answer this precisely: you get a bounded session plan with the study sized before it starts, not an open workshop calendar.
Can you train our team to run RCM instead?
Yes. The three-day RCM Foundations course teaches the seven questions, consequence categorisation, task selection and P-F interval frequency setting, and runs publicly, live online or on site on your own equipment. Most clients pair it with a facilitated first study so the capability lands with a worked example.

Is your PM program preventing failures, or just generating work?

Bring the asset class and its failure history. We will show you what an RCM study covers, how long it takes, and what changes in your CMMS when it lands.

Scope an RCM study

RCM Articles

What is Reliability Centred Maintenance? The Complete RCM Guide

What is Reliability Centred Maintenance? The Complete RCM Guide

By Dave Alexander, Managing Director, HolisticAM — Master of Maintenance and Reliability (Monash University); former Chair, Victorian Asset Management Council. Last updated: 8 September 2026. Reliability Centred Maintenance (RCM) is a structured analytical process...