| Introduction---The Recommended First Step to Rules of Thumb in Reliability Engineering |
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xiii | |
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PART I THE BASICS OF MAINTENANCE AND RELIABILITY |
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Understanding Maintenance and Reliability |
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3 | (1) |
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Strategy to Achieve World-Class Production through Reliability |
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3 | (5) |
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4 | (1) |
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Maintenance Management Philosophy |
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4 | (1) |
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The Function and Control System |
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5 | (1) |
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5 | (1) |
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6 | (1) |
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6 | (2) |
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8 | (2) |
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8 | (1) |
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Why Move Toward Proactive Work? |
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9 | (1) |
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A New Way to View Failure |
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10 | (1) |
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Maintenance/Reliability Assessment |
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10 | (4) |
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Introduction to Change Management |
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14 | (2) |
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Developing a Business Case for a Reliability Initiative |
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16 | (3) |
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Calculating Return on Investment |
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19 | (2) |
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Leadership of the ROI Team |
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19 | (1) |
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19 | (2) |
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21 | (6) |
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The Functional Maintenance Organization and Its People |
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Functional Maintenance Organizational Structure |
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27 | (2) |
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29 | (1) |
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29 | (1) |
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Environmental, Health, and Safety Aspects |
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30 | (1) |
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Maintenance Planner/Scheduler |
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30 | (1) |
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30 | (1) |
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Maintenance and Engineering Manager |
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31 | (1) |
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31 | (1) |
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Environmental, Health, and Safety Aspects |
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32 | (1) |
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Area Manager of Warehouse and Inventory Control |
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32 | (1) |
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32 | (1) |
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33 | (4) |
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34 | (1) |
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34 | (1) |
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Reliability Engineering Dashboard---Key Performance Indicators |
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35 | (2) |
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Preventive Maintenance Program |
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Reliability-Based Preventive Maintenance |
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37 | (3) |
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38 | (1) |
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38 | (1) |
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Identification of Systems |
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38 | (1) |
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Identification of System Functions |
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38 | (1) |
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38 | (2) |
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System Functional Failure and Criticality Rating |
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40 | (1) |
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Identification of Functionally Significant Items |
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40 | (1) |
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Maintenance Task Selection (Decision Logic Tree Analysis) |
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40 | (3) |
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41 | (2) |
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Paralleling and Default Logic |
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43 | (1) |
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43 | (1) |
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Task Frequencies/Intervals |
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44 | (5) |
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Predictive Maintenance Program |
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Setting Up a Preventive/Predictive Maintenance Program |
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49 | (1) |
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50 | (1) |
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50 | (3) |
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53 | (1) |
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54 | (2) |
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56 | (1) |
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Reliability Software---Managing the Health of Assets |
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57 | (6) |
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Building an Effective Asset Reliability Program |
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58 | (1) |
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Using Reliability Software to Put the Program into Action |
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58 | (1) |
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Using Handheld Devices to Collect and Upload Condition Inspection Data |
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59 | (2) |
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Plotting Asset Health Trends |
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61 | (1) |
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Capturing the Experts' Knowledge about Asset Condition |
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61 | (1) |
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Integration to Enterprise Asset Management and Computerized Maintenance Management Systems |
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62 | (1) |
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63 | (1) |
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Seven Questions Addressed by Reliability Centered Maintenance |
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63 | (3) |
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Failure Mode and Effects Analysis |
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66 | (2) |
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Equipment Criticality Analysis |
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68 | (11) |
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Preparing for an Equipment Criticality Analysis |
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71 | (1) |
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72 | (3) |
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Analyzing the Assessment Results |
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75 | (2) |
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Using the Output of the Equipment Criticality Assessment |
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77 | (1) |
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78 | (1) |
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79 | (10) |
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79 | (2) |
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81 | (2) |
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83 | (3) |
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86 | (3) |
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Key Performance Indicators |
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Defining and Understanding KPIs |
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89 | (4) |
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90 | (1) |
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91 | (2) |
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93 | (1) |
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93 | (2) |
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93 | (1) |
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Plant Management Team Dashboard |
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93 | (1) |
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Production Manager (Supervisor) Dashboard |
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94 | (1) |
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Production Operator Dashboard |
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94 | (1) |
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Maintenance Manager (Supervisor) Dashboard |
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94 | (1) |
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Maintenance Staff Dashboard |
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95 | (1) |
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Reliability Engineer Dashboard |
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95 | (1) |
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Engineering Manager Dashboard |
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95 | (1) |
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Purchasing Manager Dashboard |
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95 | (1) |
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Maintenance Stores Manager |
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95 | (1) |
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95 | (1) |
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Measuring and Managing the Maintenance Function |
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95 | (12) |
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Physical Asset Management |
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96 | (1) |
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The Asset Reliability Process |
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97 | (2) |
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Performance Metrics for the Maintenance Function |
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99 | (1) |
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Reliability Process Key Performance Indicators---Leading Measures |
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99 | (1) |
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99 | (1) |
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100 | (1) |
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100 | (1) |
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101 | (1) |
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101 | (1) |
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101 | (1) |
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Key Performance Indicators of Maintenance Effectiveness (Result Measures) |
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102 | (1) |
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The Importance of the Work Order |
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103 | (1) |
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Reporting and Use of Key Performance Indicators |
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103 | (1) |
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104 | (3) |
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Total Productive Maintenance |
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Introduction to Total Productive Maintenance |
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107 | (4) |
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107 | (1) |
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108 | (1) |
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108 | (1) |
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108 | (1) |
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108 | (1) |
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108 | (1) |
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Calculating Major Losses Is Key to TPM's Success |
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109 | (2) |
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111 | (13) |
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The Evolution from Lean Manufacturing to Lean Maintenance to Lean Reliability |
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111 | (1) |
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Managing Asset Performance to Meet Customer Needs |
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112 | (2) |
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The Basic Principles of Lean Reliability |
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114 | (3) |
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How Lean Reliability Aligns with TPM, Kaizen, Five S, and Six Sigma |
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117 | (2) |
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Key Elements to Implement and Sustain Lean Reliability |
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119 | (1) |
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120 | (4) |
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PART II EQUIPMENT AND PROCESSES |
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124 | (1) |
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Plain or Detachable-Link Chain |
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124 | (1) |
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124 | (1) |
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124 | (1) |
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124 | (1) |
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125 | (1) |
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125 | (1) |
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126 | (1) |
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126 | (1) |
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127 | (1) |
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Preventive Maintenance Procedures |
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127 | (2) |
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129 | (1) |
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129 | (1) |
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General Maintenance Person |
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129 | (1) |
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Best Maintenance Hydraulic Repair Practices |
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130 | (1) |
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Root Cause Failure Analysis |
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130 | (1) |
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130 | (2) |
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132 | (1) |
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Recommended Maintenance Modifications |
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133 | (3) |
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Shielded Metal Arc Welding (SMAW), ``Stick Welding'' |
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136 | (1) |
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Flux-Cored Arc Welding (FCAW) |
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137 | (4) |
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137 | (1) |
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137 | (4) |
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Gas-Shielded Metal Arc Welding (GMAW) |
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141 | (3) |
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GMAW for Maintenance Welding |
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141 | (1) |
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141 | (3) |
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Gas Tungsten Arc Welding (GTAW) |
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144 | (7) |
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145 | (1) |
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Advantages and Disadvantages of GTAW |
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145 | (1) |
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Principles of Operating GTAW |
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145 | (2) |
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147 | (1) |
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GTAW Shielding Gases and Flow Rates |
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147 | (1) |
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Electrode Material for GTAW |
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148 | (1) |
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GTAW Electrode Size and Tip Shape |
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148 | (1) |
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GTAW Electrode Holders and Gas Nozzles |
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149 | (1) |
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Characteristics of GTAW Power Supplies |
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149 | (1) |
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150 | (1) |
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151 | (1) |
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Establishing Welding Parameters for GTAW |
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151 | (1) |
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Gas Tungsten Arc Starting Methods |
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151 | (1) |
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151 | (1) |
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Air-Carbon Arc Cutting and Gouging |
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152 | (3) |
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153 | (1) |
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154 | (1) |
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155 | (2) |
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157 | (1) |
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157 | (1) |
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157 | (1) |
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157 | (3) |
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157 | (1) |
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158 | (2) |
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160 | (1) |
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160 | (1) |
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161 | (6) |
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161 | (1) |
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161 | (1) |
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161 | (1) |
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161 | (2) |
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Types of Surfacing Electrodes |
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163 | (1) |
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Choosing Hard-Facing Material |
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163 | (2) |
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165 | (1) |
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Check Before the Part Is Completely Worn |
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165 | (1) |
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165 | (2) |
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Selection and Maintenance of Equipment |
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167 | (2) |
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167 | (2) |
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169 | (1) |
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Installation of Equipment |
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169 | (1) |
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Equipment Operation and Maintenance |
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170 | (2) |
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Keep the Machine Clean and Cool |
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170 | (1) |
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170 | (1) |
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Do Not Work the Machine Over Its Rated Capacity |
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170 | (1) |
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170 | (1) |
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Maintain the Machine Regularly |
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170 | (2) |
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172 | (3) |
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175 | (3) |
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About a Point (Rotational) |
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175 | (1) |
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About a Line (Rotational) |
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175 | (1) |
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Along a Line (Translational) |
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175 | (3) |
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In a Plane (Rotational/Translational) |
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178 | (1) |
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Commonly Used Bearing Types |
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178 | (9) |
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178 | (4) |
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Rolling Element or Antifriction |
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182 | (3) |
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185 | (2) |
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187 | (1) |
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188 | (1) |
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188 | (1) |
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188 | (2) |
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188 | (1) |
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189 | (1) |
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Installation and General Handling Precautions |
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190 | (3) |
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Plain Bearing Installation |
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190 | (1) |
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Roller Bearing Installation |
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190 | (2) |
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General Roller-Element Bearing Handling Precautions |
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192 | (1) |
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Bearing Failures, Deficiencies, and Their Causes |
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193 | (6) |
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Improper Bearing Selection and/or Installation |
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193 | (6) |
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199 | (2) |
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199 | (2) |
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201 | (2) |
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First Law of Thermodynamics |
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201 | (1) |
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Second Law of Thermodynamics |
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202 | (1) |
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Pressure/Volume/Temperature (PVT) Relationship |
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202 | (1) |
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202 | (1) |
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Other Performance Indicators |
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202 | (1) |
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203 | (3) |
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203 | (3) |
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206 | (6) |
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207 | (3) |
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210 | (1) |
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210 | (2) |
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212 | (1) |
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212 | (13) |
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212 | (1) |
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Rotary-Type, Positive Displacement |
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212 | (4) |
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Reciprocating, Positive Displacement |
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216 | (9) |
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225 | (1) |
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Pitch Diameter and Center Distance |
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226 | (1) |
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227 | (1) |
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Diametrical Pitch and Measurement |
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227 | (1) |
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228 | (1) |
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228 | (1) |
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228 | (1) |
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229 | (1) |
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230 | (1) |
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230 | (6) |
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230 | (1) |
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231 | (1) |
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232 | (1) |
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233 | (1) |
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Gear Dynamics and Failure Modes |
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233 | (2) |
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235 | (1) |
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236 | (3) |
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237 | (1) |
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237 | (2) |
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239 | (3) |
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239 | (1) |
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239 | (3) |
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242 | (1) |
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242 | (1) |
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242 | (1) |
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242 | (6) |
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243 | (2) |
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245 | (3) |
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248 | (3) |
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248 | (1) |
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249 | (2) |
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251 | (1) |
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251 | (1) |
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251 | (1) |
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251 | (1) |
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252 | (1) |
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252 | (1) |
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V-Belt Intermediate Drives |
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252 | (1) |
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252 | (3) |
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PART III ADDITIONAL READINGS ON MAINTENANCE AND RELIABILITY |
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Top Five Reasons Why Companies Don't Measure Reliability: It Seems Like Everyone Has an Excuse as to Why They Don't Measure Reliability |
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255 | (1) |
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255 | (1) |
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255 | (1) |
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255 | (1) |
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255 | (1) |
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256 | (1) |
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Creating a Culture Change in Your Maintenance Department: Is Your Maintenance Crew in a Reactive Mindset? Check Out a List of Qualifiers to Find Out and Then Learn How to Change It |
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256 | (1) |
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Exterminate Lube Problems: Grease and Oil Expertise Can Be a Serious Competitive Edge |
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257 | (3) |
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257 | (1) |
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Make Lube Expertise a Specialty |
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258 | (2) |
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260 | (1) |
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What It Takes to Make the Climb from Reactive to RCM |
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260 | (14) |
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261 | (8) |
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Does Management Understand? |
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269 | (1) |
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270 | (1) |
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Informal versus Formal PM Programs |
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270 | (1) |
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270 | (1) |
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271 | (1) |
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272 | (1) |
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273 | (1) |
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Put a Plant-wide Focus on Functional Failures |
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274 | (1) |
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Reliability Is Worth a Second Look: Statistical Analysis and Time-Based Preventive Maintenance Don't Really Address the Ability to Perform---It's Time to Get Familiar with the Definition of Reliability |
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275 | (1) |
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When Preventive Maintenance Doesn't Work |
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276 | (1) |
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The Top Four Reasons Why Predictive Maintenance Fails and ``What to Do about It'' |
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277 | (6) |
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278 | (1) |
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Reason 1: The Collection of PdM Data Is Not Viewed as Part of the Total Maintenance Process |
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278 | (1) |
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Reason 2: The Collected PdM Data Arrives Too Late to Prevent Equipment Failures |
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279 | (1) |
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Reason 3: Many Companies Fail to Take Advantage of Data from PLCs and DCSs |
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279 | (1) |
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Reason 4: Most PdM Data Is Dispresed in Too Many Non-Integrated Databases |
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280 | (1) |
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Some Simple Guidelines Will Help to Get You Moving in the Right Direction |
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281 | (1) |
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282 | (1) |
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Understanding Definitions |
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283 | (1) |
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283 | (1) |
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284 | (1) |
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284 | (1) |
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284 | (1) |
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284 | (31) |
| Appendix |
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| Workflow for Planning |
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| Appendix |
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| Checklists and Forms |
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| Glossary |
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315 | (4) |
| Index |
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319 | |
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