Reliability. Maintenance. and. Best Practices. Second Edition. Ramesh Gulati, cmrp, cre, p.e. Industrial Press, Inc.

Transcription

1 Maintenance and Reliability Best Practices Second Edition Ramesh Gulati, cmrp, cre, p.e. Foreword by Terrence O'Hanlon, CMRP Industrial Press, Inc.

2 Table of Contents Foreword to the Second Edition Preface and Acknowledgements to the Second Edition Preface to the First Edition Acknowledgements to the First Edition xiii xv xvii xix Chapter 1 Introducing Best Practices Introduction: What Is a Best Practice? Key Terms and Definitions What Do Best Practices Have to Do with Maintenance and Reliability? Examples of Maintenance and Reliability Benchmarks Basic Test on Maintenance and Reliability Knowledge Summary Self Assessment Questions References and Suggested Reading 18 Chapter 2 Culture and Leadership Introduction Key Terms and Definitions Leadership and Organizational Culture Strategic Framework: Vision, Mission, and Goals Change Management Reliability Culture Measures of Performance Summary Self Assessment Questions References and Suggested Reading 47 vii

3 viii Chapter 3 Understanding Maintenance Introduction Key Terms and Definitions Maintenance Approaches Other Maintenance Practices Maintenance Management System: CMMS Maintenance Quality Maintenance Assessment and Improvement Summary Self Assessment Questions References and Suggested Reading 80 Chapter 4 Work Management: Planning and Scheduling Introduction Key Terms and Definitions Work Flow and Roles Work Classification and Prioritization Planning Process Scheduling Process Turnarounds and Shutdowns Measures of Performance Summary Self Assessment Questions References and Suggested Reading 115 Chapter 5 Materials, Parts, and Inventory Management Introduction Key Terms and Definitions Types of Inventory Physical Layout and Storage Equipment 128

4 ix 5.5 Optimizing Tools and Techniques Measures of Performance Summary Self Assessment Questions References and Suggested Reading 149 Chapter 6 Measuring and Designing for Reliability and Maintainability Introduction Key Terms and Definitions Defining and. Measuring Reliability and Other Terms Designing and Building for Maintenance and Reliability Summary Self Assessment Questions References and Suggested Reading 186 Chapter 7 Operator Driven Reliability Introduction Key Terms and Definitions The Role of Operations Total Productive Maintenance (TPM) Workplace Organization: 5S Overall Equipment Effectiveness (OEE) Measures of Performance Summary Self Assessment Questions References and Suggested Reading 217 Chapter 8 Maintenance Optimization Introduction Key Terms and Definitions 221

5 RCM X 8.3 Understanding Failures and Maintenance Strategies Maintenance Strategy Maintenance Strategy CBM Other Maintenance Strategies Summary Self Assessment Questions References and Suggested Reading 282 Chapter 9 Managing Performance Introduction Key Terms and Definitions Identifying Performance Measures Data Collection and Data Quality Benchmarking and Benchmarks Summary Self Assessment Questions References and Suggested Reading 307 Chapter 10 Workforce Management Introduction Key Terms and Definitions Employee Life Cycle Understanding the Generation Gap Communication Skills People Development Resource Management and Organization Structure Measures of Performance Summary Self Assessment Questions References and Suggested Reading 349

6 xi Chapter 11 Maintenance Analysis and Improvement Tools Introduction Key Terms and Definitions Maintenance Root Cause Analysis Tools Six Sigma and Quality Maintenance Tools Lean Maintenance Tools Other Analysis and Improvement Tools Summary Self Assessment Questions References and Suggested Reading 399 Chapter 12 Current Trends and Practices Introduction Key Terms and Definitions Sustainability, Energy Management, and the Green Initiative Personnel, Facility, and Arc Flash Safety Risk Management Corrosion Control Systems Engineering and Configuration Management Standards and Standardization Summary Self Assessment Questions References and Suggested Reading 450 Appendixfor Chapter Best Practices Q-A: Answer Key and Explanation 451 Index 467