Maintenance Resource Management : Adapting Materials Requirements Planning MRP

176 Pages·2014·2.64 MB·English

by  Bhadbury

Maintenance Resources Management
Maintenance Resources
Management Adapting MRP
DINESH SHENOY
Index Computing, Bangalore, India
BIKASH BHADURY
Indian Institute of Technology, Kharagpur, India
This edition published in the Taylor & Francis e-Library, 2005.
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Copyright © Dinesh Shenoy and Bikash Bhadury 1998
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, electrostatic, magnetic
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the copyright owner.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
ISBN 0-203-21251-7 Master e-book ISBN
ISBN 0-203-26983-7 (Adobe eReader Format)
ISBN 0-7484-0648-4 (cased)
Library of Congress Cataloging in Publication Data are available
Cover design by Ian Youngs
To the maintenance managers
Contents
Foreword x
Preface xii
Acknowledgements xv
1 Maintenance, its Organisation and Management 1
1.1 History of Maintenance 1
1.2 Maintenance Management—An Overview 3
1.3 Definition of Maintenance 4
1.4 Objectives and Functions of Maintenance 5
1.5 Quality Aspects in Maintenance 8
1.6 Maintenance Organisation 7
1.6.1 Initial Level 9
1.6.2 Repeatable Level 9
1.6.3 Defined Level 10
1.6.4 Managed Level 10
1.6.5 Optimised Level 10
1.7 Improving Maturity in Maintenance Organisations 10
1.7.1 Training Strategy 11
1.7.2 Work Management 11
1.7.3 Resources Management 15
1.7.4 Supervisory Review 15
1.7.5 Quality Assurance 15
1.7.6 Subcontract Management 15
1.8 Dynamics of a Maintenance Organisation 17
vi
1.9 Maintenance Management Perspectives 18
1.10 Types of Maintenance 19
1.10.1 Preventive Maintenance 20
1.10.2 Corrective Maintenance 23
1.10.3 Shut-down Maintenance 24
1.10.4 Opportunistic Maintenance 24
1.11 Summary 24
1.12 References 25
2 Management of Maintenance Resources 27
2.1 Manpower 27
2.2 Spare Parts 28
2.2.1 Statistical Inventory Theory Models 28
2.2.1.1 Inventory Costs 28
2.2.1.2 How Much to Order? 29
2.2.1.3 When to Order? 29
2.2.2 Selective Inventory Control Procedures 31
2.2.3 Manufacturing Resources Planning 33
2.2.3.1 The Bill of Materials 33
2.2.3.2 Master Production Schedule 36
2.2.3.3 Inventory Status File 36
2.2.3.4 Processing Logic 37
2.2.3.5 Item Lead-times 38
2.2.3.6 Requirements Pegging 39
2.2.3.7 Rescheduling Process 39
2.2.3.8 Capacity Requirements Planning 39
2.3 Tools and Facilities 43
2.4 Effect of Maintenance Types on Resources 43
2.5 Comparison of Resources Management Techniques 44
2.6 Summary 45
vii
2.7 References 47
3 Maintenance Management—Adapting MRP 50
3.1 Limitations of MRP 50
3.2 Basic Alterations 51
3.3 Components of an MRP-based Maintenance Resources 53
Management System
3.3.1 Master Maintenance Schedule 53
3.3.1.1 Recommendations Made by Original Equipment 57
Manufacturers
3.3.1.2 Achieving an Output of a Predetermined Quantity 58
3.3.1.3 Simulation 59
3.3.1.4 Usage of Condition Monitoring Techniques 61
3.3.1.5 Multi-stream Markov Chains 62
3.3.1.6 Using Neural Networks 63
3.3.2 Bills of Maintenance 64
3.3.2.1 Bill of Preventive Maintenance 65
3.3.2.2 Bill of Corrective Maintenance 67
3.3.3 Processing Logic 71
3.3.3.1 Case 1: Replacement of Defective Parts 72
3.3.3.2 Case 2: Repair of Defective Parts 73
3.3.4 Resource Status File 74
3.3.5 Computing Requirements 76
3.3.6 Capacity Requirements Planning 77
3.4 Executing the Maintenance Plan 79
3.5 Other System Outputs 81
3.6 Summary 83
3.7 References 85
4 Case Application 87
4.1 Managing Resources for a Thermal Power Unit 87
4.1.1 Background 87
viii
4.1.2 Current Scenario 87
4.1.2.1 Spare Parts and Other Maintenance Materials 87
4.1.2.2 Maintenance Skills Requirements 89
4.1.3 The Fuel System 89
4.1.4 Bills of Maintenance 92
4.1.5 Simulation Modelling 93
4.1.6 Verification and Testing 95
4.1.7 Detection of Initial Bias 96
4.1.8 Simulation Experiments and Results 98
4.2 Other Case Applications—A Note 1 05
4.3 Summary 1 07
4.4 References 1 08
5 Maintenance Management Information Systems: Design 1 09
Specifications
5.1 Objectives of an Information System 1 09
5.2 Functional Requirements 1 10
5.2.1 Equipment Maintenance Function 1 10
5.2.2 Work Order Management Function 1 10
5.2.3 Inventory Management Function 1 11
5.2.4 Vendor Management Function 1 11
5.2.5 Subcontractor Management Function 1 11
5.2.6 General Information Systems Specifications 1 11
5.3 Capturing the Flow of Data 1 12
5.4 Designing the Information System 1 13
5.4.1 Database Design 1 13
5.4.1.1 Creating a Data Model 1 13
5.4.1.2 Creating a Physical Database 1 14
5.4.2 Design of User Interface 1 15
5.4.3 Reports and Inquiry Design 1 25
5.5 Summary 1 28
ix
5.6 References 1 29
6 Concluding Remarks 1 32
6.1 About MRSRP 1 32
6.1.1 MRSRP—An Integrated Approach to Maintenance Resources 1 34
Management
6.1.2 Decision Support System—A Tool for Effective Implementation1 37
6.2 Implementing the MRP-based Maintenance Resource 1 37
Management System
6.2.1 New Horizons 1 38
6.2.2 Hurdles and Stumbling Blocks 1 40
6.2.2.1 Resistance to Change—Changing Attitude of People 1 40
6.2.2.2 Availability of Required Maintenance Data 1 41
6.3 A Few Suggestions for Further Research 1 42
6.3.1 Enlarging the Bills of Maintenance 1 42
6.3.2 Repair Shop Scheduling 1 44
6.3.3 Integrating the Decision Support System 1 46
6.4 References 1 46
Appendix A 1 47
Appendix B 1 50
Appendix C 1 51
Appendix D 1 53
Appendix E 1 54
Index 1 55