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Über dieses Buch

Analyzing maintenance as an integrated system with objectives, strategies and processes that need to be planned, designed, engineered, and controlled using statistical and optimization techniques, the theme of this book is the strategic holistic system approach for maintenance. This approach enables maintenance decision makers to view maintenance as a provider of a competitive edge not a necessary evil.

Encompassing maintenance systems; maintenance strategic and capacity planning, planned and preventive maintenance, work measurements and standards, material (spares) control, maintenance operations and control, planning and scheduling, maintenance quality, training, and others, this book gives readers an understanding of the relevant methodology and how to apply it to real-world problems in industry.

Each chapter includes a number exercises and is suitable as a textbook or a reference for a professionals and practitioners whilst being of interest to industrial engineering, mechanical engineering, electrical engineering, and industrial management students. It can also be used as a textbook for short courses on maintenance in industry.

This text is the second edition of the book, which has four new chapters added and three chapters are revised substantially to reflect development in maintenance since the publication of the first edition. The new chapters cover reliability centered maintenance, total productive maintenance, e-maintenance and maintenance performance, productivity and continuous improvement.

Inhaltsverzeichnis

Frontmatter

Chapter 1. Maintenance Systems

Abstract
This chapter provides an overview and highlights the key features of the book. In addition, it presents the components of a typical maintenance system that need to be planned, organized, and optimized, in order to maximize the output of a maintenance system and achieve organization objectives with the best utilization of resources. In addition, the chapter introduces the strategic system approach to maintenance and provides synopsis of the book chapters. The chapter is concluded by a list of standard maintenance terms.
Salih O. Duffuaa, A. Raouf

Chapter 2. Maintenance Strategic and Capacity Planning

Abstract
The theme of this chapter is planning and techniques required for accomplishing it. Strategic and capacity planning are the main subjects of this chapter. The techniques covered include: quantitative and qualitative forecasting, deterministic and stochastic techniques for capacity planning. The capacity planning techniques presented are linear programming, queuing, and simulation. The applications of these techniques in maintenance are demonstrated.
Salih O. Duffuaa, A. Raouf

Chapter 3. Preventive Maintenance, Concepts, Modeling, and Analysis

Abstract
The purpose of this chapter is to present elements of planned and preventive maintenance concepts and models. Preventive maintenance concepts are presented, followed by a host of diagnostic techniques which are useful for implementing condition-based maintenance programs. Then, this chapter presents a host of mathematical models for optimal preventive maintenance and replacement, followed by mathematical models for inspections. The inspections models aid in determining frequency of inspections that are useful for planning effective maintenance actions. In addition, the chapter presents the concepts of imperfect maintenance and delay time modeling. Several examples are provided to illustrate the concepts and the models.
Salih O. Duffuaa, A. Raouf

Chapter 4. Maintenance Work Measurement

Abstract
The effectiveness of maintenance operations management can be substantially improved if goals to evaluate and improve the performance of such operations are established and implemented. An essential and necessary prerequisite for evaluating productivity and performance of maintenance is the availability of job standards. The purpose of this chapter is to present techniques for developing jobs time standards. The techniques presented include: work measurement techniques, work sampling, pre-determined motion time systems, standard data, and estimation. A number of examples are provided to demonstrate the concepts.
Salih O. Duffuaa, A. Raouf

Chapter 5. Maintenance Material Control

Abstract
One critical cost of maintenance is investment in spares and materials. If the investment becomes excessive, the results are high capital costs and high maintenance costs. On the other hand, if the spares and material needed for repair and servicing the equipment are not available when needed, the cost of down time will increase immensely. Efforts to balance the cost of stocking maintenance material and spares against the cost of down time are needed to achieve an effective maintenance material control system. This chapter describes approaches for developing a maintenance material control system that will help provide the needed level of maintenance in an economical manner.
Salih O. Duffuaa, A. Raouf

Chapter 6. Maintenance Operations and Control

Abstract
An effective maintenance operation and control system is the backbone of sound assets management. Controlling maintenance means coordinating of demand for maintenance and available resources to achieve a desired level of effectiveness and efficiency. This chapter addresses maintenance operations and control systems. It explains the necessary forms and procedures for the operations and accomplishments of maintenance work. The concept of the maintenance control cycle is explained followed by the work order system. Procedures and forms used for reporting and recording data are provided. The structure of maintenance control and a host of effective engineered maintenance programs for improving the effectiveness of the maintenance control system are outlined.
Salih O. Duffuaa, A. Raouf

Chapter 7. Maintenance Planning and Scheduling

Abstract
Effective planning and scheduling contribute significantly to reduced maintenance costs, improved utilization of maintenance resources, and better quality of maintenance work. An essential part of planning and scheduling is to be able to forecast future work and to balance the work load. The maintenance management system should aim to have over 90% of the maintenance work planned and scheduled in order to reap the benefits of planning and scheduling. This chapter presents the ingredients and the techniques for effective planning and scheduling. It covers the elements of planning and the ingredients of sound scheduling. The techniques for scheduling and turnaround maintenance are discussed.
Salih O. Duffuaa, A. Raouf

Chapter 8. Maintenance Quality Control

Abstract
The development of a sound quality control system for maintenance is essential for ensuring high quality repair, accurate standards, maximum availability, and efficient equipment production rates. Quality control as an integrated system has been practiced with more intensity in production and manufacturing operations than in maintenance. Although the role of maintenance in the long-term profitability in an organization has been realized, the issues relating to the quality of maintenance output has not been adequately formulated. This chapter presents the elements of maintenance quality control. Responsibilities of quality control departments within maintenance and, inspection and testing programs ae described. The use of statistical process control in maintenance and quality circles are highlighted.
Salih O. Duffuaa, A. Raouf

Chapter 9. Maintenance Training

Abstract
This chapter introduces skill and skill levels, type of training, a framework for indicating an appropriate training program and means of evaluating the effectiveness of such training programs in the context of maintenance. Skill levels and maintenance training activities are discussed in detail.
Salih O. Duffuaa, A. Raouf

Chapter 10. Computerized Maintenance Management Systems

Abstract
A Computerized maintenance management system (CMMS) is basically an information system adapted to serve maintenance. CMMS aids in the process of data collection, recording, storing, updating, processing, communicating, and forecasting. It is essential for planning, scheduling, and controlling the maintenance activities. Through effective reporting a CMMS can provide maintenance managers and engineers with the information needed for sound decision making to control and improve the maintenance process. This chapter presents the elements of an effective CMMS and outlines a systematic procedure for their evaluation. An overview of a CMMS and its modules are presented. Effective maintenance reporting through CMMS is discussed and finally a procedure for evaluating CMMSs is provided.
Salih O. Duffuaa, A. Raouf

Chapter 11. Reliability-Centered Maintenance

Abstract
Reliability Centered Maintenance is a logical methodology derived from research in the aviation sector and uses the failure mode, effect, and criticality analysis (FMECA) tool. RCM is a process used to identify the most applicable and effective maintenance action(s) to ensure the highest practical standard of operating performance of a system or a component. The purpose of this chapter is to present RCM as a viable approach for optimizing maintenance of systems by having an optimal mix of run to failure, time-based, condition-based, and design modification maintenance tasks. RCM principles and benefits reaped from RCM are presented first, followed by the concept of failure and its nature and RCM steps. In addition, RCM implementation is outlined.
Salih O. Duffuaa, A. Raouf

Chapter 12. Total Productive Maintenance

Abstract
TPM is defined as a management approach to maintenance that imports total quality management (TQM) philosophy and techniques to maintenance. TPM focuses on involving all employees in the organization in equipment improvement. TPM started in Japan and has spread to the Far East, Europe, South America, and the United States. It became a recognized methodology for improving equipment reliability and plant productivity. TPM eliminates losses resulting from unplanned down time, reduced speed, and quality. TPM brought to industry over all equipment effectiveness (OEE) as a measure that combines losses from unplanned down time, reduced speed and quality. The purpose of this chapter is to present the concepts and implementation of TPM. In this chapter, the goals and the key elements of TPM are outlined. Equipment management is discussed followed by the description of TPM implementation.
Salih O. Duffuaa, A. Raouf

Chapter 13. Intelligent Maintenance

Abstract
The purpose of this chapter is to present e-maintenance and intelligent maintenance (i-maintenance) systems, a relatively new approach to maintenance engineering and management. An intelligent maintenance system (IMS) is a system that utilizes the collected data from equipment and machinery in order to predict and prevent the potential failures. Today e-maintenance became a very common term in the maintenance literature and many companies such as Canon, American Petroleum Institute (API), British Petroleum (BP) and American Telephone & Telegraph (AT&T) is advertising on the internet e-maintenance programs for their products. Predictive maintenance and element of e-maintenance are presented in this chapter. Then the implementation of e-maintenance is discussed including requirements and barriers.
Salih O. Duffuaa, A. Raouf

Chapter 14. Maintenance System Performance, Productivity, and Continuous Improvement

Abstract
Productivity and continues improvement of maintenance systems is the subject of this chapter. Continuous improvement of maintenance systems may be achieved using three approaches. The first approach is to use performance measures and the second approach is to conduct periodic auditing of the maintenance system. The third approach is to combine both approaches. In the first approach performance measures for the maintenance system are defined and computed on periodic basis. Targets are set and based on the system performance and the targets improvement programs are developed and implemented. In the second approach the regular audits are used to identify areas to improve the system. In this chapter a set of input, output and within the system measures together with the balanced scorecard are presented. Maintenance indices for administration, effectiveness, and cost followed by metric comparisons are provided. Then the chapter focuses on maintenance auditing and root causes analysis for developing corrective and preventive actions that is expected to result in continuous improvement. The chapter is concluded by a case study on maintenance, followed by benchmarking techniques.
Salih O. Duffuaa, A. Raouf

Backmatter

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