Maintenance Engineering and Management

Transcription

1 Maintenance Engineering and Management Smooth running Condition monitoring Performance change detectable Condition monitoring Impending failure Failed K. Venkataraman

2 Maintenance Engineering and Management

3

4 Maintenance Engineering and Management K. Venkataraman Birla Institute of Technology & Science, Pilani Chennai Centre New Delhi

5 Rs MAINTENANCE ENGINEERING AND MANAGEMENT K. Venkataraman 2007 by PHI Learning Private Limited, New Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN The export rights of this book are vested solely with the publisher. Fourth Printing October, 2010 Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus, New Delhi and Printed by Mudrak, 30-A, Patparganj, Delhi

6

7 Contents Preface xi 1. Introduction to Maintenance Systems Introduction Definitions of Repair and Maintenance Maintenance as Business Proposition The Business Unit Concept Automation Maintenance Cost Reduction History of Maintenance Business Maintenance Philosophy Different Maintenance Systems Planned Maintenance Preventive Maintenance Predictive Maintenance Proactive Maintenance Maintenance Policies and Procedures Manual Man Management Issues in Maintenance Function Concept of Supervision 12 Summary 15 Review Questions 15 Annexure 1 Benefits of Planned Maintenance Departmentwise 16 Annexure 2 Typical Failure Report and Action Taken Maintainability Introduction Measure of Maintainability Failure Rate Curves Typical Bathtub Type of Failure Pattern Inherent and Operational Availability Testability and Supportability Methods of Evaluation of Maintainability Procedure in Sampling and Testing Test Plan for Determination of MTTR (Mean Time to Repair or Maintainability) Computerized Evaluation of MTTRs and Other Related Parameters Design for Maintainability An Overview Some Guidelines for a Good Design for Maintenance 28

8 vi Contents Benefits of Deploying Design for Maintainability Capabilities of a Proven Design System Incorporating Design for Maintenance Designs for Reliability 31 Summary 32 Review Questions Condition-Based Maintenance (CBM) Introduction Effectiveness Improvement through Condition Monitoring Vibration Analysis Ultrasonic Evaluation Motor Condition Monitor Thermography Oil and Lubricant Analysis in CBM Methods of Analysis of Oil and Lubricants Degradation of Grease Case Study of Engine Oils, Transmission Oil and Drive Train Oils Gas-Leakage Detection Alignment of Shafts Typical Case Study Non-destructive Testing (NDT) Techniques Types of Non-destructive Testing Comparative Analysis of NDT Techniques Retirement for Cause 49 Summary 51 Review Questions 51 Annexure 1 Equipment for Carrying Out Condition-Based Maintenance 52 Annexure 2 Thermography Reliability-Centred Maintenance (RCM) Introduction Practical Steps Towards Achieving Reliability-Centred Maintenance Reliability Block Diagrams Reliability While Being Active and Standby Other General Features of Redundant Systems Reliability-Centred Maintenance Basic Guidelines of Reliability-Centred Maintenance Case Study of Implementing RCM Techniques in Railways Other Analytical Tools Failure Modes Effects and Criticality Analysis (FMECA) Root Cause Failure Analysis (RCFA) Logic Tree in Maintenance Management or in Root Cause Analysis Criticality Analysis/Criticality Matrix Difference between RCM and RCA (Root Cause Analysis) 76

9 vii Contents 4.8 Event Tree Analysis Prediction Model for Reliability Use of Software in Carrying Out Reliability-Centred Maintenance 78 Summary 80 Review Questions Asset and Spare Parts Management Introduction Asset Management Function in 21st Century Organizations Financial Asset Management Human Asset Management Physical Asset Management Comparative Analysis of Asset Functions Conventional Systems of Ordering Spare Parts and Materials Economic Order Quantity Two-Bin System of Material Procurement 5.6 Materials Management Manual Proven, and New Approaches in Effective Asset/Spare Parts Management Programme Mobile Computing and Use of Bar Code Technology for Spare Parts Tracking and Monitoring 96 Summary 98 Review Questions 99 Annexure Key Definitions Safety Engineering and Fault Tree Analysis Introduction Hazard Analysis Codes and Standards in Occupational Safety and Health (OSH) Benefits of Occupational Safety Case Study of an Automobile Repair Shop Hazard Prevention Hazards due to Faulty Work Habits or Conditions Hazards due to Equipment Defects Types of Fire Extinguishers (Figures 6.4 and 6.5) and Their Applications Salient Points in the Safe Maintenance Work of An Automobile General Rules in Fire Hazard and Safety Electrical Hazards Hazards Caused due to Ergonomics Smoking Chemical Hazard and Prevention Responsibilities of Supervisors in Safety Programme Evaluation Procedures in Safety Fault Tree Analysis Purpose of Fault Tree Analysis 115

10 viii Contents Description of Fault Tree Analysis Nomenclature of Various Symbols in Fault Tree Sneak Circuit Analysis Failure Mechanisms 118 Summary 119 Review Questions 119 Annexure Important Definitions on Safety Total Productive Maintenance Introduction TPM Methodology of Working The Big Six Wastes Which are Being Eliminated by TPM Total Productive Maintenance Origin of the Concept of TPM Implementation of TPM Major Road Map of TPM World-Class Maintenance Organization Lean Maintenance Training and Mentoring for Implementation of Proactive Maintenance/Total Productive Maintenance/Lean Maintenance Mentoring Training by Example Metrics for Measurement of Culture Change Business-Centred Maintenance 133 Summary 133 Review Questions Maintenance Planning and Scheduling Introduction Maintenance Planning Shutdown Planning and Execution Salient Features of Shutdown Planning and Execution Monitoring of Shutdown Function Sequencing of Activities in a Machine Shutdown Review of the Effectiveness of Proactive Shutdown 143 Summary 144 Review Questions Computer Applications in Maintenance Management Introduction Determining the Business Objectives and the Role of CMMS Data Acquisition The Wireless Method 150

11 Maintenance Engineering And Management 25% OFF Publisher : PHI Learning ISBN : Author : VENKATARAMAN, K. Type the URL : Get this ebook