DEPARTMENT OF THE NAVY

OFFICE OF THE CHIEF OF NAVAL OPERATIONS

2000 NAVY PENTAGON
WASHINGTON, DC 20350-2000

OPNAVINST 4790.16B
N43
1 Oct 2015

OPNAV INSTRUCTION 4790.16B

From: Chief of Naval Operations

Subj: CONDITION-BASED MAINTENANCE AND CONDITION-BASED

MAINTENANCE PLUS POLICY

Ref: (a) DoD Instruction 4151.22 of 16 October 2012

(b) DoD MIL-STD 3034A, DoD Standard Practice Reliability
Centered Maintenance Process, 29 April 2014
(c) SECNAVINST 5030.8B
(d) DoD Instruction 5000.02 of 7 January 2015
(e) OPNAVINST 4700.7L
(f) NAVAIRINST 4790.20B
(g) NAVSEAINST 4790.27A
(h) SECNAV M-5239.1 of 1 November 2005
(i) DoD Instruction 8500.01 of 14 March 2014
(j) NAVSEA SL720-AA-MAN-030
(k) OPNAVINST 1000.16L

Encl: (1) Definitions

1. Purpose

a. To establish policy and responsibility, per reference

(a), for the implementation and integration of condition-based
maintenance (CBM) and condition-based maintenance plus (CBM+) for
naval ships, expeditionary equipment, aircraft, and associated
systems, equipment and infrastructure.

b. This revision incorporates policy changes for

implementing CBM+ and follows standards set by reference (a), and
for implementing CBM+ within maintenance practices. It also
includes new language for reliability centered maintenance (RCM)
and CBM+ that is in line with references (a) and (b). This
instruction is a complete revision and should be reviewed in its
entirety.

2. Cancellation. OPNAVINST 4790.16A.

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1 Oct 15

3. Scope. This instruction applies to acquisition, logistics,

and maintenance activities for all new and legacy programs. CBM
and CBM+ concepts, as described in reference (a), apply to all
active and reserve naval ships, aircrafts, and the systems
associated with them, as well as the infrastructure which
supports them. Throughout this instruction, the term “ship”
refers to all surface ships, aircraft carriers, submarines, and
those patrol and service craft specified in reference (c). The
fundamental goal of CBM is to perform maintenance only when
there is objective evidence of need, while ensuring safety,
equipment reliability, equipment availability, and reduction of
total ownership costs (TOC). The evidence of need is
objectively determined through RCM analysis.

4. Definitions. Applicable definitions are in enclosure (1).

5. Background

a. Maintenance comprises a major portion of TOC for Navy

systems and equipment. Unnecessary maintenance contributes to
inflated ownership costs and reduced readiness of deployable
assets. Proper application of CBM+ strategies, as part of an
overall acquisition or modernization plan per reference (d),
will reduce operating and support costs, avoid extensive
maintenance man hours, and increase operational readiness. CBM+
is the implementation of CBM by integrating RCM derived
maintenance requirements with enabling processes, technologies,
and capabilities that enhance the readiness and maintenance
effectiveness of Department of Defense (DoD) systems and
components. CBM+ strategy consists of the technical requirements
for CBM including infrastructure and programmatic elements that
enable it to function as a true end-to-end process.

b. At the core of Navy maintenance, RCM, defined in

references (b), (e), (f) and (g), provides the principles and
rigorous methodology needed to select the appropriate type of
maintenance. RCM is the foundation upon which a CBM program is
built. CBM, utilizing CBM+ technologies, establishes an
integrated, predictive maintenance approach, which minimizes
unscheduled repairs, eliminates unnecessary maintenance, and
employs the most cost-effective maintenance health management
methods. When implemented effectively, RCM and CBM+-enabling
technologies can reduce maintenance and supportability
requirements. Recent advances in RCM and CBM+ enabling

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technologies (e.g., advanced signal processing techniques,

neural networks and fuzzy logic, high speed image processing,
serialized item management, unique identification (UID), dynamic
modeling and simulation, micro-electromechanical systems,
wireless data communications, and health monitoring systems) are
expected to provide significant improvements in safety,
availability, reliability, and affordability.

6. Policy

a. RCM must be used to select the appropriate type of

maintenance trigger for Navy equipment and systems. RCM must be
used to extend periodicities or eliminate unnecessary scheduled
maintenance requirements based on maintenance data and operating
experience, as applicable. Additionally, RCM must be used as
the means to identify gaps in existing maintenance programs and
to add or modify tasks to alleviate deficiencies.

b. CBM+ must provide a basis for maintenance decisions that

focus limited resources on maintenance most needed to ensure
safety and mission readiness.

c. Organic monitoring and control systems must be utilized

where applicable to aid in failure analysis and optimize
maintenance planning.

d. The transition to CBM+ involves changes in policy,

processes, procedures, information systems, and logistics
support. To this end, maintenance programs must incorporate CBM+
strategy to the maximum possible extent, where proven cost
effective through business case analysis.

e. CBM+ strategy must be used to:

(1) Determine maintenance decisions and optimize

calendar-based scheduled maintenance, unscheduled maintenance,
and manpower requirements, while reducing operating and
sustainment costs and ensuring appropriate maintenance is
performed.

(2) Minimize equipment failures and improve operational

availability by providing real-time prognostic and diagnostic
monitoring capabilities, automated repair scheduling, updating

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preventive maintenance schedules, and automated parts

acquisition processes for afloat and ashore warfighting and
infrastructure systems across the Navy.

(3) Reduce TOC by eliminating unnecessary maintenance

and accurately pre-positioning required assets for an effective
logistics footprint in support of war fighting requirements.

f. CBM+ policy must be incorporated into existing

maintenance programs and into the integrated product support
program elements for systems and equipment under acquisition.
Navy policy directs that CBM+ must be documented in the system
engineering plan and the life cycle sustainment plan program,
and assessed during acquisition process reviews and evaluations
per reference (d).

g. For legacy systems, rapid system demonstration and

testing is desired to evaluate CBM+ technologies. Initial
logistics support need only be sufficient to ensure valid
testing and proof-of-concept. Prior to comprehensive and
repetitive installation of CBM+ supported systems or equipment,
complete logistics support is required.

h. CBM+ implementation must include training for maintenance

managers, technicians afloat, technical support personnel
ashore, and maintenance requirements developers. Embedded and
on-board training capabilities must be identified in training
plan documentation.

i. CBM+ enabling technologies must comply with DoD

architecture framework initiatives and related standards
concerning interoperability and openness. CBM+ enabling
information systems (data collection, diagnostics and
prognostics, and information analysis) must be integrated with
maintenance management and logistics support information
systems. The impact of information systems data collection,
processing, and warehousing requirements on afloat and ashore
resources must be included in system design, development, and
life-cycle planning.

j. All CBM+ technologies must be compliant with Navy

information assurance and cybersecurity policies per references
(h) and (i).

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k. Chief of Naval Operations (CNO) will fund naval

programs, processes, and enabling technologies proven applicable
and effective in supporting the maintenance, manning, and cost
reduction objectives of this instruction, following the entitled
process in reference (j).

l. CBM+ metrics must be tracked as specified in reference

(a).

7. Responsibilities

a. Director, Naval Nuclear Propulsion (CNO (N00N)).

Executive Order 12344 establishes the responsibilities and
authorities of CNO (N00N), who also serves as the Deputy
Commander, Naval Sea Systems Command, and as Deputy Assistant
Secretary for Reactors, U.S. Department of Energy, over all
facilities and activities which comprise the Naval Nuclear
Propulsion Program. These responsibilities and authorities
include all matters pertaining to maintenance, repair, and
modification of naval propulsion plants and associated nuclear
capable facilities. Nothing in this instruction supersedes or
changes these responsibilities and authorities. Accordingly,
CNO (N00N) must determine policies and practices pertaining to
implementation of this instruction for matters under his or her
cognizance.

b. Deputy Chief of Naval Operations for Information

Dominance (CNO (N2/N6)); Office of the Chief of Naval Operations
(OPNAV) Director, Strategic Mobility and Combat Logistics (OPNAV
(N42)); OPNAV Director, Expeditionary Warfare (OPNAV (N95));
OPNAV Director, Surface Warfare (OPNAV (N96)); OPNAV Director,
Undersea Warfare (OPNAV (N97)); OPNAV Director, Air Warfare
(OPNAV (N98)); and OPNAV Director, Warfare Integration (OPNAV
(N9I))

(1) Establish requirements and specific platform

guidance for the development, test and evaluation, and
implementation of CBM+.

(2) Evaluate the installation and testing results of CBM+

enabling technologies with the goal of further refinement and
follow-on installation of those items with the greatest
potential for cost and manpower savings.

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(3) Provide resource sponsorship for the installation of

approved CBM+ enabling technologies in cognizant platforms,
systems, and equipment, as well as CBM+ enabling processes and
procedures and continuous training.

(4) Identify and promote the application of appropriate

common CBM+ processes, procedures, and technologies across
applicable naval platforms.

c. Deputy Chief of Naval Operations for Manpower,

Personnel, Training and Education (CNO (N1))

(1) Coordinate the implementation of innovative manpower

reduction initiatives resulting from the implementation of CBM+
policies, processes, and procedures, and the installation of CBM+
enabling technologies.

(2) Ensure fleet manpower documents reflect changes in

manpower requirements resulting from installation of CBM+
enabling technologies and from workload reductions resulting
from other CBM+ related initiatives per reference (k).

d. OPNAV Director, Fleet Readiness Division (OPNAV (N43)).

Provide Navy policy for the development of CBM+.

e. OPNAV Director, Innovation, Technology Requirements and

Test and Evaluation (OPNAV (N84/ONR))

(1) Identify science and technology (S&T) requirements

for advancing CBM+ enabling technologies in close coordination
with CNO, program executive offices (PEO), naval systems
commands (SYSCOM), and fleet commanders.

(2) Plan, develop, and coordinate the transitioning of

technologies responding to CBM+ S&T requirements.

(3) Coordinate with all SYSCOMs and PEOs the

demonstration and rapid transition of requirements-driven CBM+
enabling technologies in Navy systems and platforms.

(4) As the S&T resource sponsor, conduct periodic

assessments of the OPNAV (N84/ONR) CBM S&T program with respect
to requirements.

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f. Director, Strategic Systems Program. Determine policies

and practices pertaining to implementation of this instruction
for matters under his or her cognizance.

g. SYSCOMs

(1) Support CNO and PEO in the testing and assessment of

CBM+ processes, procedures, and enabling technologies with the
goal of reducing maintenance costs, extending periodicities, or
eliminating unnecessary scheduled maintenance requirements for
applicable systems and equipment.

(a) Maintain a cross-competency working group to

facilitate CBM+ identification and implementation opportunities
at the program level and across the naval enterprise.

(b) SYSCOM leads for CBM+ must advise OPNAV resource

sponsors on CBM+ related initiatives to include identification of
investment costs, readiness improvements, and potential savings.

(2) Provide technical support for installation,

compatibility, and interface of shipboard information management
systems and CBM+ automated health monitoring systems. Promote
compliance with networks and information integration initiatives
and standards for shipboard information, local area network, and
CBM+ enabling technologies.

(3) Support the development, integration and

standardization of CBM+ technologies into modernization and
engineering development efforts.

(4) Support the continual improvement and advancements

of CBM+ technologies by providing procedures and initial training
to maintenance managers, technicians afloat, technical support
personnel ashore, and maintenance requirements developers.
Ensure professional development training courses, embedded and
on-board training capabilities are identified in training plan
documentation.

(5) Review and coordinate platform-specific CBM+

initiatives that would reduce maintenance, personnel workload,
and life cycle costs.

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(6) Provide engineering support for CBM+ implementation

on cognizant platforms and promote application of CBM+
technologies across all applicable platforms to CNO, PEO, fleet
commanders, and other SYSCOMs.

(7) Under the principles of open systems architecture,

develop a standard data format, interface standards for sensors,
information technology, and data management that will serve as
the enabling foundation for CBM+ capabilities that acquisition
managers must use in the development and implementation of
afloat and ashore CBM+ systems.

h. Fleet Commanders

(1) Identify and promote the implementation of proven

CBM+ processes, procedures, enabling technologies, and
maintenance effectiveness reviews to appropriate SYSCOMs.

(2) Provide operational assessment of CBM+ effectiveness

to the PEOs and SYSCOMs recommending changes to CBM+
implementation plans and policy.

(3) Coordinate platform availability for the development

and demonstration of emerging CBM+ technologies.

i. PEOs

(1) Support program offices through coordination and

promotion of common CBM+ technologies and processes with multi-
platform applications.

(2) Support commonality and standardization reviews

focusing on products, components, and equipment that may be
applicable and for use within the planned system design and
development. Coordinate with the SYSCOM CBM+ working groups as
appropriate, to expand the use of successful CBM+ initiatives
across as many programs as is possible.

(3) Provide recommendations for further development or

improvement of CBM+ equipment and systems installed for testing
and evaluation.

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(4) Promote full scale implementation of appropriate CBM+

technologies on existing and new construction platforms.

(5) Ensure that CBM+ requirements are documented in the

system engineering plan and life cycle sustainment plan program,
and supported during each acquisition process review.

(6) Ensure professional development training courses,

embedded and on-board training capabilities, are identified in
the training plan documentation.

j. Budget Submitting Offices. Ensure shore manpower

requirements reflect changes in manpower requirements resulting
from installation of CBM+ enabling technologies, and from
workload reductions resulting from other CBM+ related
initiatives, per reference (k).

8. Records Management. Records created as a result of this

instruction, regardless of media and format, must be managed per
Secretary of the Navy Manual 5210.1 of January 2012.

P. H. CULLOM
Deputy Chief of Naval Operations
(Fleet Readiness and Logistics)

Distribution:
Electronic only, via Department of the Navy Issuances Web site
http://doni.documentservices.dla.mil

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DEFINITIONS

1. Condition-Based Maintenance (CBM). CBM is a maintenance

strategy derived from analysis, using DoD approved RCM
principles. CBM includes maintenance processes and capabilities
derived from real or near-real time assessments obtained from
embedded sensors and external tests and measurements using
either portable equipment or actual inspection. The objective
of CBM is to perform maintenance based upon the evidence of need
in order to ensure safety, reliability, and availability, at an
acceptable TOC.

2. Condition-Based Maintenance Plus (CBM+). CBM+ is the

application and integration of appropriate processes,
technologies, and knowledge-based capabilities to achieve the
target availability, reliability, and operation and support
costs of DoD systems and components across their life cycle. At
its core, CBM+ is maintenance performed based on evidence of
need, integrating RCM analysis with those enabling processes,
technologies, and capabilities that enhance the readiness and
maintenance effectiveness of DoD systems and components. CBM+
uses a systems engineering approach to collect data, enable
analysis, and support the decision-making processes for system
acquisition, modernization, sustainment, and operations.

3. Maintenance Effectiveness Review. An RCM-based review of

all levels of maintenance utilizing combined SYSCOM, fleet, and
engineering integrated teams. The maintenance effectiveness
review process applies “Backfit” and “Classic” RCM methodology
to examine maintenance requirements for systems or equipment
that are exhibiting negative maintenance and reliability trends
in execution, such as extra cost through the execution of
unnecessary maintenance overtime or the discovery of low
reliability due to ineffective maintenance.

4. Preventive or Scheduled Maintenance. Maintenance that can

be based on calendar, equipment-operating time, or a cycle, such
as number of starts, aircraft landings, rounds fired, or miles
driven.

5. Predictive Maintenance. The use of analytic processes to

estimate the future (predicted) level of remaining service life

Enclosure (1)
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to initiate advance maintenance planning and scheduling. In

some cases, a prediction is not viable, but only a diagnostic
(current health) assessment can be made.

6. Reliability. The probability that an item will perform a

required function under stated conditions for a specified period
of time.

7. Reliability Centered Maintenance (RCM). A method for

determining maintenance requirements based on the analysis of
the likely functional failures of systems or equipment having a
significant impact on safety, operations, and lifecycle cost.
RCM supports the failure management strategy for any system
based on its inherent reliability and operating context.

8. Serialized Item Management (SIM). SIM programs provide

accurate and timely item-related data that identify populations
of select items (parts, components, and end items) and mark all
items in the population with a UID number to enable the
generation, collection and analysis of maintenance data about
each specific item. Candidate item populations include:
repairable items down to and including sub-component repairable
unit level; life-limited, time-controlled, or items with records
(e.g., logbooks, aeronautical equipment service records); and
items that require technical directive tracking at the part
number level. See DoD Instruction 4151.19 of 9 January 2014 for
more information.

9. Unique Identification (UID). DoD program that enables easy

access to information about DoD possessions that will make
acquisition, repair, and deployment of items faster and more
efficient. UID permanently identifies an individual item and is
a system of establishing globally ubiquitous unique identifiers
within the DoD, which serves to distinguish a discrete entity or
relationship from other like and unlike entities or
relationships. UID connects processes such as financial
transactions, contracting, logistics, maintenance and
engineering. Harnessing this data power will reduce
organizational costs in the near and long term, which is the key
to success and is a mandatory requirement for all DoD
solicitations issued on or after 1 January 2004. See DoD
Directive 8320.03 of 23 March 2007 for more information.

2 Enclosure (1)