Maintenance and Reliability Best Practices

by Ramesh Gulati, Ricky Smith

ISBN13: 9780831133115

ISBN10: 0831133112

Format: Hardcover

Pub. Date: 2009-08-03

Publisher(s): INDUSTRIAL PRESS

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Summary

Drawing upon the author's many years of shop floor and management experience in a variety of industries, this book is designed to provide a basic yet thorough understanding of Maintenance and Reliability "Best Practices." It will be helpful to both the novice and seasoned professional alike, and the contents are presented in an easy-to-understand style and format. This book recognizes that to implement best practices requires a workforce with a thorough understanding and knowledge of Maintenance and Reliability principles and available technologies. But implementation is not as simple as just putting something new into effect. To truly implement a best practice requires learning, relearning, bench-marking, and realizing better ways of ensuring high reliability and availability of equipment and systems. This book explains and supports this ongoing process, and is an essential guide and reference for everyone who wants to ensure that their company's assets are operating as and when needed and at reasonable cost. Book jacket.

Author Biography

Ramesh Gulati is currently Asset Management and Reliability Planning Manager with Aerospace Testing Alliance at Arnold Engineering Development Center (AEDC), Arnold AFB, TN. In this position he is responsible for creating a reliability culture across AEDC and for building and designing reliability into new systems. Previously, he held various maintenance, engineering, and management positions at AEDC, Carrier Air Conditioning Corp., True Temper Corp., Bethlehem Steel, and Heavy Engineering Corporation's Foundry Forge Plant. Ramesh is a Certified Maintenance Reliability Professional (CMRP), Certified Reliability Engineer (CRE), and registered Professional Engineer (PE). He holds BSME, MSIE, and MBA degrees, is very active in professional societies and has authored many professional papers. Currently, he is Director of Certification and Standards for SMRP and a Board member. He also serves as an advisory Board member of the University of Tennessee's Maintenance Reliability Center (MRC) and is a Fellow of the Institute of Industrial Engineering (IIE).

Foreword	p. ix
Preface	p. xi
Acknowledgements	p. xiii
Introducing Best Practices	p. 1
What Is a Best Practice?	p. 2
Understanding Maintenance and Reliability	p. 3
Examples of Maintenance and Reliability Benchmarks	p. 6
Basic Test on Maintenance and Reliability Knowledge	p. 9
Key Terms and Definitions	p. 18
Summary	p. 21
References and Suggested Reading	p. 22
Culture and Leadership	p. 23
Introduction	p. 24
Leadership and Organizational Culture	p. 28
Strategic Framework: Vision, Mission, and Goals	p. 30
Reliability Culture	p. 38
Summary	p. 42
References and Suggested Reading	p. 43
Understanding Maintenance	p. 45
Introduction	p. 46
Maintenance Work Tasks	p. 49
Other Maintenance Practices	p. 62
Maintenance Quality and Tasks Optimization	p. 65
Measuring Maintenance Performance	p. 67
Summary	p. 68
References and Suggested Reading	p. 69
Work Management: Planning and Scheduling	p. 71
Introduction	p. 72
Work Flow and Roles	p. 76
Planning Process	p. 80
Scheduling Process	p. 86
Turnaround and Shutdowns	p. 91
Measures of Performance	p. 96
Summary	p. 97
References and Suggested Reading	p. 97
Materials, Parts, and Inventory Management	p. 99
Introduction	p. 100
Types of Inventory	p. 103
Physical Layout and Storage Equipment	p. 109
Optimizing Tools and Techniques	p. 114
Performance Measures and Indicators	p. 125
Summary	p. 125
References and Suggested Reading	p. 126
Measuring and Designing for Reliability and Maintainability	p. 127
Introduction	p. 128
Defining and Measuring Reliability and Other Terms	p. 133
Designing and Building for Maintenance and Reliability	p. 150
Summary	p. 158
References and Suggested Reading	p. 159
The Role of Operations	p. 161
Introduction	p. 162
The Role of Operations	p. 163
Total Productive Maintenance (TPM)	p. 167
Workplace Organization: 5 S	p. 176
Performance Measures: Metrics	p. 181
Summary	p. 186
References and Suggested Reading	p. 188
PM Optimization	p. 189
Introduction	p. 190
Understanding Failure	p. 193
PM Optimizing Tools	p. 194
Summary	p. 243
References and Suggested Reading	p. 244
Managing Performance	p. 245
Introduction	p. 246
Identifying Performance Measures	p. 250
Benchmarking and Benchmarks	p. 259
Data Collection and Data Quality	p. 264
Summary	p. 267
References and Suggested Reading	p. 268
Workforce Management	p. 273
Introduction	p. 274
Employee Life Cycle	p. 276
Understanding the Generation Gap	p. 278
People Development	p. 284
Workforce Management	p. 292
Summary	p. 300
References and Suggested Reading	p. 302
M & R Analysis Tools	p. 303
Introduction	p. 304
Analysis Tools	p. 308
Computerized Maintenance Management System	p. 344
Summary	p. 355
References and Suggested Reading	p. 355
Current Trends and Practices	p. 357
Arc Flash Hazards and Prevention	p. 358
Communication and Problem Solving Skills	p. 365
Energy Conservation and Green Initiative	p. 372
Lean Management and Maintenance	p. 382
Safety and Reliability	p. 387
Systems Engineering and Configuration Management	p. 394
References and Suggested Reading	p. 400
Answer Key and Explanations	p. 401
Supplemental Glossary	p. 411
Index	p. 412
Table of Contents provided by Ingram. All Rights Reserved.