Planning and control of maintenance systems: modeling and analysis
Gespeichert in:
Hauptverfasser: | , , |
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Format: | Buch |
Sprache: | English |
Veröffentlicht: |
New York [u.a.]
Wiley
1999
|
Schlagworte: | |
Online-Zugang: | Inhaltsverzeichnis |
Beschreibung: | XXIV, 371 S.: graph. Darst. |
ISBN: | 0471179817 |
Internformat
MARC
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035 | |a (DE-599)BVBBV012529060 | ||
040 | |a DE-604 |b ger |e rakddb | ||
041 | 0 | |a eng | |
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050 | 0 | |a TS192 | |
082 | 0 | |a 658.2/02 |2 21 | |
084 | |a QP 544 |0 (DE-625)141902: |2 rvk | ||
100 | 1 | |a Duffuaa, Salih O. |e Verfasser |4 aut | |
245 | 1 | 0 | |a Planning and control of maintenance systems |b modeling and analysis |c Salih O. Duffuaa ; A. Raouf ; John Dixon Campbell |
264 | 1 | |a New York [u.a.] |b Wiley |c 1999 | |
300 | |a XXIV, 371 S.: graph. Darst. | ||
336 | |b txt |2 rdacontent | ||
337 | |b n |2 rdamedia | ||
338 | |b nc |2 rdacarrier | ||
650 | 7 | |a Fabriekscomplexen |2 gtt | |
650 | 4 | |a Fábricas, conservación y reparación - Administración | |
650 | 4 | |a Fábricas, conservación y reparación - Planeación | |
650 | 7 | |a Management |2 gtt | |
650 | 7 | |a Onderhoud |2 gtt | |
650 | 4 | |a Plant maintenance |x Management | |
650 | 4 | |a Plant maintenance |x Planning | |
650 | 0 | 7 | |a Instandhaltungsplanung |0 (DE-588)4200074-9 |2 gnd |9 rswk-swf |
689 | 0 | 0 | |a Instandhaltungsplanung |0 (DE-588)4200074-9 |D s |
689 | 0 | |5 DE-604 | |
700 | 1 | |a Raouf, Abdul |e Verfasser |4 aut | |
700 | 1 | |a Campbell, John Dixon |e Verfasser |4 aut | |
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999 | |a oai:aleph.bib-bvb.de:BVB01-008506044 |
Datensatz im Suchindex
_version_ | 1804127174736740352 |
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adam_text | CONTENTS
Preface xvii
Acknowledgments xxi
About the Authors xxiii
1 Maintenance Systems 1
1.1 Introduction 1
1.2 Planning Activities 3
1.2.1 Maintenance Philosophy 4
1.2.2 Maintenance Load Forecasting 6
1.2.3 Maintenance Capacity Planning 7
1.2.4 Maintenance Organization 8
1.2.5 Maintenance Scheduling 8
1.3 Organizing Activities 9
1.3.1 Job Design 10
1.3.2 Time Standards 10
1.3.3 Project Management 10
1.4 Control Activities 11
1.4.1 Work Control 11
1.4.2 Inventory Control 11
1.4.3 Cost Control 11
1.4.4 Quality Control 12
1.5 Managing for Quality and Training 12
1.6 Human Behavior 13
1.7 Maintenance Terms 13
Summary 15
Exercises 15
Selected Bibliography 16
vii
viii CONTENTS
2 Maintenance Operations and Control 17
2.1 Introduction 17
2.2 Maintenance Control Cycle 18
2.3 Maintenance Work Order System 19
2.3.1 Design of the Work Order 20
2.3.2 Work Order System Flow 23
2.4 Record Keeping 24
2.4.1 Job Card (Report) 25
2.4.2 Equipment History Record 25
2.5 Structure of Maintenance Control 27
2.5.1 Work Order Coordination and Planning 28
2.6 Work Order Processing 30
2.7 Information Feedback and Corrective Action 31
2.7.1 Work Control 32
2.7.2 Cost Control 35
2.7.3 Quality Control 37
2.7.4 Plant Condition Control 37
2.8 Effective Engineered Maintenance Program 38
2.8.1 Planned Maintenance 38
2.8.2 Emergency Maintenance 38
2.8.3 Reliability Improvement 39
2.8.4 Equipment Management Program 39
2.8.5 Cost Reduction 40
2.8.6 Training and Employee Motivation 40
Summary 41
Exercises 42
Selected Bibliography 42
3 Preventive Maintenance, Concepts, Modeling,
and Analysis 43
3.1 Introduction 43
3.2 Preventive Maintenance 45
3.3 Diagnostic Technologies 49
3.3.1 Vibration Analysis 51
3.3.2 Oil Analysis 52
3.3.3 Thermography 52
3.3.4 Ultrasonics 52
CONTENTS ix
3.3.5 Electrical Effects Monitoring 53
3.3.6 Penetrants 53
3.4 Replacement Decision Models 53
3.5 Elements of Planned Maintenance 56
3.5.1 Plan Administration 56
3.5.2 Facility Inventory 57
3.5.3 Identification of Equipment 57
3.5.4 Facility Register 57
3.5.5 Maintenance Schedule 57
3.5.6 Job Specification 58
3.5.7 The Maintenance Program 58
3.5.8 Program Control 58
3.6 Mathematical Models for Optimum Preventive
Maintenance Policies 58
3.6.1 Optimal Age Based Preventive Replacement
(Type I Policy) 59
3.6.2 Golden Section Method 61
3.6.3 Optimal Constant Interval Preventive
Replacement (Type II Policy) 66
3.6.4 Extension of Policies I and II 68
3.7 Inspection Models 70
3.7.1 Optimal Inspection Schedule Minimizing
Expected Cost for a Single Machine 72
3.7.2 Profit Maximization Model for a Single
Machine Inspection 73
3.7.3 Inspection Model to Minimize Expected
Cost with Minimal Repair 73
3.7.4 Model for Coordinating the Inspection of a
Group of Machines 75
3.8 Imperfect Preventive Maintenance 78
3.8.1 Model Assumptions and Notation 78
3.8.2 Approach 1 Model 79
3.8.3 Approach 2 Model 81
3.8.4 Approach 3 Model 82
3.9 Delay Time Modeling 83
Summary 86
Exercises 86
References 88
x CONTENTS
4 Maintenance Work Measurement 90
4.1 Introduction 90
4.2 Work Measurement Techniques 91
4.2.1 Time Study 92
4.2.2 Time Study Procedure 92
4.3 Work Sampling 97
4.3.1 Number of Observations Required for a
Work Sampling Study 99
4.3.2 Planning a Work Sampling Study 99
4.4 Control Charts 102
4.4.1 Introduction 102
4.4.2 Control Chart Construction 102
4.5 Predetermined Motion Time Systems 103
4.5.1 MTM 2 System 104
4.5.2 Procedure for Setting a Predetermined
Standard 105
4.6 Standard Data 105
4.6.1 Introduction 106
4.6.2 Steps for Developing Standard Data 106
4.7 Estimating 106
4.7.1 Introduction 106
4.7.2 Comparative Estimating (Slotting) 106
4.7.3 Applying Comparative Estimating 108
Summary 110
Exercises 111
Selected Bibliography 111
5 Maintenance Forecasting and Capacity Planning 112
5.1 Introduction 112
5.2 Forecasting Preliminaries 113
5.3 Qualitative Forecasting Techniques 114
5.4 Quantitative Forecasting Techniques 116
5.4.1 Simple Moving Average 116
5.4.2 Weighted Moving Average 117
5.4.3 Regression Analysis 118
5.4.4 Exponential Smoothing 122
5.4.5 Seasonal Forecasting 125
CONTENTS xi
5.5 Error Analysis 129
5.6 Forecasting Maintenance Work 130
5.7 Maintenance Capacity Planning 131
5.8 Deterministic Approaches for Capacity Planning 133
5.8.1 Heuristic Tableau Method 133
5.8.2 Linear and Integer Programming for
Capacity Planning 139
5.9 Stochastic Techniques for Capacity Planning 144
5.9.1 Queuing Models 145
5.9.2 Stochastic Simulation 148
5.10 Contract Maintenance 151
Summary 152
Exercises 153
References 155
6 Maintenance Planning and Scheduling 156
6.1 Introduction 156
6.2 Planning 158
6.3 Scheduling 161
6.3.1 Elements of Sound Scheduling 162
6.4 Maintenance Job Priority System 164
6.5 Scheduling Techniques 164
6.5.1 Mathematical Programming Approaches
for Maintenance Scheduling 167
6.5.2 Critical Path Method 168
6.5.3 Program Evaluation Review Technique 176
6.5.4 Integer and Stochastic Programming
Approaches for Maintenance Scheduling 177
6.6 Turnaround Maintenance 183
6.6.1 Turnaround Maintenance Planning 188
6.6.2 Turnaround Schedule 186
6.6.3 Turnaround Maintenance Reporting 188
Summary 188
Appendix 189
Exercises 190
References 191
xii CONTENTS
7 Maintenance Material Control 193
7.1 Introduction 193
7.2 Maintenance Store Components 194
7.2.1 Spare Parts 194
7.2.2 Normal Maintenance Stock 194
7.2.3 Tools 195
7.3 Maintenance Material Costs 195
7.3.1 Cost of the Item 195
7.3.2 Cost of Inventorying the Item 195
7.3.3 Cost of the Item at Its Time of Issue 195
7.4 Maintenance Store Control Procedure 197
7.4.1 Requisition 197
7.4.2 Inventory Control 197
7.4.3 Items to Be Stocked 197
7.4.4 ABC Analysis 198
7.5 Inventory Systems 199
7.5.1 Economic Order Quantity 200
7.5.2 Reorder Level 202
7.5.3 Safety Stock 203
7.5.4 Effective Ordering Policy 205
7.6 Ordering Policies for Repairs 205
7.6.1 Demand and Failure Rate Linkage 206
7.6.2 Estimating Units of Spares Needed for
Replacing Failures 206
7.7 Spare Parts Classification 209
7.7.1 Spare Parts Ordering Strategies Based
on Classification 210
7.7.2 Grouping Spares According to Criticality
and Cost 210
Summary 211
Exercises 211
References 212
8 Maintenance Quality Control 213
8.1 Introduction 213
8.2 Responsibilities of Quality Control 215
8.3 Inspection and Check Programs 216
CONTENTS xiii
8.4 Statistical Process Control in Maintenance 217
8.4.1 Data Collection 217
8.4.2 Checklist 217
8.4.3 Histogram 221
8.4.4 Cause and Effect (Fishbone) Diagram 222
8.4.5 Pareto Chart (ABC Analysis) 226
8.4.6 Control Charts 227
8.4.7 Scatter Diagram 228
8.4.8 Failure Mode and Effect Analysis 229
8.5 Maintenance Job Quality Control 229
8.5.1 Factors Related to Procedures and
Standards 231
8.5.2 Factors Related to Personnel 231
8.5.3 Factors Related to Material 231
8.5.4 Factors Related to Tools and Equipment 234
8.6 Quality Circles 234
8.7 Maintenance Link to Quality 236
Summary 239
Exercises 239
References 240
9 Productivity of Maintenance Systems 242
9.1 Introduction 242
9.2 Input Measures 242
9.3 Output Measures 244
9.4 Measures Within the System 249
9.5 Maintenance Indices 250
9.5.1 Maintenance Administration 250
9.5.2 Maintenance Effectiveness 252
9.5.3 Maintenance Costs 253
9.6 Metric Comparisons 253
9.7 Trend Analysis 256
Summary 256
Exercises 256
References 257
xiv CONTENTS
10 Computerized Maintenance Management Systems 258
10.1 Introduction 258
10.2 Overview of Computerized Maintenance
Management Systems 259
10.3 CMMS Modules 261
10.3.1 Equipment Management Module 262
10.3.2 Work Order Control Module 262
10.3.3 Worker Management Module 266
10.3.4 Material Supply and Control Module 266
10.3.5 Performance Reporting Module 268
10.3.6 Maintenance Reporting 271
10.4 Evaluation of Computerized Maintenance
Management Systems 273
10.5 Evolution of CMMS for Effective Maintenance 275
Summary 280
Exercises 281
References 281
11 Maintenance Training 283
11.1 Introduction 283
11.2 Skill 284
11.2.1 Skill Levels 284
11.3 Maintenance Training Activities 285
11.3.1 Training Policy 285
11.3.2 Evaluating Current Status 286
11.3.3 Need Analysis 287
11.3.4 Designing the Training Program 289
11.3.5 Implementation of the Training Program 289
11.3.6 Evaluating Effectiveness 290
Summary 291
Exercises 292
Selected Bibliography 292
12 Maintenance Audit and Continuous Improvement
of Maintenance Systems 293
12.1 Introduction 293
12.2 Factors in the Audit Scoring Scheme 294
12.2.1 Organization and Staffing 294
CONTENTS xv
12.2.2 Labor Productivity 296
12.2.3 Management Training 296
12.2.4 Planner Training 296
12.2.5 Worker Training 296
12.2.6 Motivation 296
12.2.7 Management and Budget Control 297
12.2.8 Work Order Planning and Scheduling 297
12.2.9 Facilities 297
12.2.10 Stores, Material, and Tool Control 2970
12.2.11 Preventive Maintenance and Equipment
History 297
12.2.12 Engineering and Condition Monitoring 298
12.2.13 Work Measurement and Incentives 298
12.2.14 Information System 298
12.3 Analytical Hierarchy Process for Determining
the Weights of Factors 298
12.4 ABC (Pareto Chart) Analysis 301
12.5 Root Cause Analysis and Possible Corrective
Action 302
12.5.1 Organization and Staffing 303
12.5.2 Labor Productivity 303
12.5.3 Management Training 303
12.5.4 Planner Training 304
12.5.5 Worker Training 304
12.5.6 Motivation 304
12.5.7 Management and Budget Control 305
12.5.8 Work Order Planning and Scheduling 305
12.5.9 Facilities 305
12.5.10 Stores, Material, and Tool Control 305
12.5.11 Preventive Maintenance and Equipment
History 305
12.5.12 Engineering and Condition Monitoring 306
12.5.13 Work Measurement and Incentives 306
12.5.14 Information System 306
12.6 Case Study for Maintenance Productivity
Improvement 307
Summary 308
Exercises 309
References 309
xvi CONTENTS
13 Advances in Maintenance Concepts 311
13.1 Introduction 311
13.2 Design for Maintainability 312
13.3 Reliability Centered Maintenance 314
13.4 Total Productive Maintenance 317
13.4.1 Employee Empowerment 318
13.4.2 Equipment Management 318
13.4.3 TPM Implementation 321
13.5 Benchmarking and World Class Maintenance 322
13.6 Maintenance Process Reengineering 323
13.6.1 Process Analysis 324
13.6.2 Activity Based Costing 325
13.6.3 Competitive Benchmarking 328
Summary 328
Exercises 328
References 329
Appendix A Statistical Review 330
Appendix B Reliability and Failure Analysis 359
Appendix C Optimization Methods 362
Index 000
|
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indexdate | 2024-07-09T18:29:10Z |
institution | BVB |
isbn | 0471179817 |
language | English |
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physical | XXIV, 371 S.: graph. Darst. |
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spelling | Duffuaa, Salih O. Verfasser aut Planning and control of maintenance systems modeling and analysis Salih O. Duffuaa ; A. Raouf ; John Dixon Campbell New York [u.a.] Wiley 1999 XXIV, 371 S.: graph. Darst. txt rdacontent n rdamedia nc rdacarrier Fabriekscomplexen gtt Fábricas, conservación y reparación - Administración Fábricas, conservación y reparación - Planeación Management gtt Onderhoud gtt Plant maintenance Management Plant maintenance Planning Instandhaltungsplanung (DE-588)4200074-9 gnd rswk-swf Instandhaltungsplanung (DE-588)4200074-9 s DE-604 Raouf, Abdul Verfasser aut Campbell, John Dixon Verfasser aut HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=008506044&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
spellingShingle | Duffuaa, Salih O. Raouf, Abdul Campbell, John Dixon Planning and control of maintenance systems modeling and analysis Fabriekscomplexen gtt Fábricas, conservación y reparación - Administración Fábricas, conservación y reparación - Planeación Management gtt Onderhoud gtt Plant maintenance Management Plant maintenance Planning Instandhaltungsplanung (DE-588)4200074-9 gnd |
subject_GND | (DE-588)4200074-9 |
title | Planning and control of maintenance systems modeling and analysis |
title_auth | Planning and control of maintenance systems modeling and analysis |
title_exact_search | Planning and control of maintenance systems modeling and analysis |
title_full | Planning and control of maintenance systems modeling and analysis Salih O. Duffuaa ; A. Raouf ; John Dixon Campbell |
title_fullStr | Planning and control of maintenance systems modeling and analysis Salih O. Duffuaa ; A. Raouf ; John Dixon Campbell |
title_full_unstemmed | Planning and control of maintenance systems modeling and analysis Salih O. Duffuaa ; A. Raouf ; John Dixon Campbell |
title_short | Planning and control of maintenance systems |
title_sort | planning and control of maintenance systems modeling and analysis |
title_sub | modeling and analysis |
topic | Fabriekscomplexen gtt Fábricas, conservación y reparación - Administración Fábricas, conservación y reparación - Planeación Management gtt Onderhoud gtt Plant maintenance Management Plant maintenance Planning Instandhaltungsplanung (DE-588)4200074-9 gnd |
topic_facet | Fabriekscomplexen Fábricas, conservación y reparación - Administración Fábricas, conservación y reparación - Planeación Management Onderhoud Plant maintenance Management Plant maintenance Planning Instandhaltungsplanung |
url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=008506044&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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