Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM) PDF
Preview Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM)
Equipment Management in the Post-Maintenance Era A New Alternative to Total Productive Maintenance (TPM) Equipment Management in the Post-Maintenance Era A New Alternative to Total Productive Maintenance (TPM) KERN PENG CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2012 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20111122 International Standard Book Number-13: 978-1-4665-0197-3 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmit- ted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright. com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com This book is dedicated to my wife, Patricia, who is the coach of my pursuits, and to my two daughters, Ilena and Elena, who are the cheerleaders along my journey. Contents List of Figures .....................................................................................xiii List of Tables .........................................................................................xv Preface .................................................................................................xvii Acknowledgments ...............................................................................xxi About the Author ..............................................................................xxiii Section i introduction to equipment Management chapter 1 Introduction .......................................................................3 Background ..................................................................................3 Maintenance Management ........................................................6 Equipment Management ............................................................7 Key Equipment Terminology .....................................................8 Equipment States ....................................................................8 Equipment Time .....................................................................8 Equipment Actions ...............................................................11 Equipment Failure Patterns ................................................12 Equipment Performance Measurements ...........................14 chapter 2 History of Equipment Management ...............................17 Introduction ...............................................................................17 Phase 1: Breakdown Management ..........................................17 Phase 2: Preventive Maintenance ............................................18 Phase 3: Productive Maintenance ..........................................20 Phase 4: Total Productive Maintenance .................................22 Phase 5: TPM with Predictive Maintenance..........................25 Summary of the Pre-maintenance and Maintenance Phases ..........................................................................................26 vii viii • Contents chapter 3 Introduction to the Post-Maintenance Era ....................29 The New Business Environment .............................................29 Operational Changes...........................................................30 Equipment Characteristics ..................................................31 New Enabling Technologies ................................................33 New Management Concepts ...............................................35 The Issues of Maintenance .......................................................36 Problems in Objectives ........................................................37 Structural Inefficiency..........................................................38 Unsuitable for Changing Environment .............................39 Introduction to Phase 6: Post-Maintenance Era ..................40 Section ii the Maintenance System chapter 4 General Maintenance Concepts and Practices ..............45 Introduction ...............................................................................45 Preventive Maintenance ...........................................................45 Preventive Maintenance Schedule......................................47 Preventive Maintenance Task List ......................................50 Preventive Maintenance Staffing Requirements ..............52 Preventive Maintenance Equipment/Tool Requirements ........................................................................53 Preventive Maintenance Materials/Parts Requirements ...54 Preventive Maintenance Information System .................54 Reliability-Centered Maintenance ..........................................55 Predictive Maintenance ............................................................58 Maintenance Prevention ..........................................................61 Total Productive Maintenance ................................................63 Terotechnology ..........................................................................65 chapter 5 Maintenance Management Logistics ..............................67 Introduction ...............................................................................67 Planning and Budgeting ...........................................................67 Strategic Planning in Maintenance ...................................68 Headcount Plan .....................................................................70 Budget Plan ............................................................................75 Tactical Planning in Maintenance .....................................82 Contents • ix Training and People Development .........................................85 Customer Services and Management .....................................92 Vendor, Supplier, and Contract Management .......................95 Inventory Management .........................................................100 chapter 6 Maintenance Performance Indicators ..........................105 Introduction .............................................................................105 Equipment Performance Indicators ......................................106 Safety Indicators .................................................................106 Purpose ............................................................................106 Format and Variation ....................................................106 Presentation ....................................................................107 Availability Indicators ........................................................107 Purpose ............................................................................107 Format and Variation ....................................................108 Presentation ....................................................................109 Reliability Indicators ..........................................................110 Purpose ............................................................................110 Format and Variation ....................................................110 Presentation ....................................................................112 Maintainability Indicators ................................................113 Purpose ............................................................................113 Format and Variation ....................................................113 Presentation ....................................................................114 Utilization Indicators .........................................................115 Purpose ............................................................................115 Format and Variation ....................................................116 Presentation ....................................................................117 Process Performance Indicators ............................................117 Labor Productivity Indicators...........................................118 Purpose ............................................................................118 Format and Variation ....................................................118 Presentation ....................................................................119 Nonproductive Downtime Indicators .............................119 Purpose ............................................................................119 Format and Variation ...................................................120 Presentation ...................................................................120 x • Contents Customer Satisfaction Indicators .....................................121 Purpose ............................................................................121 Format and Variation ....................................................121 Presentation ...................................................................122 Operational Misses and Error Rates ...............................122 Purpose ...........................................................................122 Format and Variation ...................................................122 Presentation ...................................................................123 Cost Performance Indicators ................................................124 Cost Rates ...........................................................................124 Purpose ...........................................................................124 Format and Variation ...................................................124 Presentation ....................................................................125 Cost Breakdown by Categories .........................................125 Purpose ............................................................................125 Format and Variation ...................................................126 Presentation ...................................................................126 chapter 7 Computerized Maintenance Management Systems .....127 Introduction .............................................................................127 CMMS Objectives ..................................................................128 CMMS Functions ....................................................................132 Equipment Module .............................................................132 Work Order Module ...........................................................132 Preventive Maintenance Module ......................................133 Safety Module .....................................................................134 Labor Module .....................................................................134 Inventory Module ..............................................................134 Financial Module ................................................................135 Calendar Module ................................................................135 CMMS Features .......................................................................136 Accessibility and Security..................................................136 Communication and Notification ....................................137 Data Entry and Presentation .............................................138 Integration ...........................................................................139 Flexibility and Customization ..........................................140 CMMS Implementation ..........................................................141
Description:The list of books you might like
