Rules of thumb for maintenance and reliability engineers:
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| Main Author: | |
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| Format: | Book |
| Language: | English |
| Published: |
Amsterdam [u.a.]
Elsevier
2008
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| Subjects: | |
| Online Access: | Table of contents only Inhaltsverzeichnis |
| Physical Description: | XIII, 320 S. Ill., graph. Darst. |
| ISBN: | 0750678623 9780750678629 |
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MARC
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| 020 | |a 9780750678629 |9 978-0-7506-7862-9 | ||
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| 100 | 1 | |a Smith, Ricky |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Rules of thumb for maintenance and reliability engineers |c Ricky Smith ; R. Keith Mobley |
| 264 | 1 | |a Amsterdam [u.a.] |b Elsevier |c 2008 | |
| 300 | |a XIII, 320 S. |b Ill., graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 650 | 4 | |a Fiabilité | |
| 650 | 4 | |a Güvenilirlik | |
| 650 | 4 | |a Maintenabilité | |
| 650 | 4 | |a Sistem mühendisliği - Yönetim | |
| 650 | 4 | |a Systems engineering |x Management | |
| 650 | 4 | |a Reliability | |
| 700 | 1 | |a Mobley, R. Keith |e Sonstige |4 oth | |
| 856 | 4 | |u http://www.loc.gov/catdir/toc/ecip0717/2007019635.html |3 Table of contents only | |
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| 999 | |a oai:aleph.bib-bvb.de:BVB01-016162786 | ||
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| adam_text | RULES OF THUMB F OR MAINTENANCE AND RELIABILITY ENGINEERS RICKY SMITH R.
KEITH MOBLEY AMSTERDAM * BOSTON * HEIDELBERG * LONDON NEW YORK * OXFORD
* PARIS * SAN DIEGO SAN FRANCISCO * SINGAPORE * SYDNEY * TOKYO ELSEVTER
BUTTERWORTH-HEINEMANN IS AN IMPRINT OF ELSEVIER CONTENTS
INTRODUCTION*THE RECOMMENDED FIRST STEP TO RULES OF THUMB IN RELIABILITY
ENGINEERING XIII P A R T I THE BASICS OF MAINTENANCE AND RELIABILITY
1.5. INTRODUCTION TO CHANGE MANAGEMENT 14 1.6. DEVELOPING A BUSINESS
CASE FOR A RELIABILITY INITIATIVE 16 1.7. CALCULATING RETURN ON
INVESTMENT 19 1.7.1. LEADERSHIP OF THE ROI TEAM 19 1.7.2. CASE STUDY 19
1.8. PLANNING AND SCHEDULING 21 C H A P T E R C H A P T E R
UNDERSTANDING MAINTENANCE AND RELIABILITY 1.1. THE MAINTENANCE FUNCTION
3 1.2. STRATEGY TO ACHIEVE WORLD-CLASS PRODUCTION THROUGH RELIABILITY 3
1.2.1. MAINTENANCE APPROACHES 4 1.2.2. MAINTENANCE MANAGEMENT PHILOSOPHY
4 1.2.3. THE FUNCTION AND CONTROL SYSTEM 5 1.2.4. WHAT IS MAINTENANCE? 5
1.2.5. SPECIFICATION 6 1.2.6. THE MAINTENANCE FUNCTION 6 1.3. WHAT IS
RELIABILITY? 8 1.3.1. COMPANIES THAT GET IT 8 1.3.2. WHY MOVE TOWARD
PROACTIVE WORK? 9 1.3.3. A NEW WAY TO VIEW FAILURE 10 1.4.
MAINTENANCE/RELIABILITY ASSESSMENT 10 THE FUNCTIONAL MAINTENANCE
ORGANIZATION AND ITS PEOPLE 2.1. FUNCTIONAL MAINTENANCE ORGANIZATIONAL
STRUCTURE 27 2.2. MAINTENANCE SUPERVISOR 29 2.2.1. RESPONSIBILITIES 29
2.2.2. ENVIRONMENTAL, HEALTH, AND SAFETY ASPECTS 30 2.3. MAINTENANCE
PLANNER/SCHEDULER 30 2.3.1. RESPONSIBILITIES 30 2.4. MAINTENANCE AND
ENGINEERING MANAGER 31 2.4.1. RESPONSIBILITIES 31 2.4.2. ENVIRONMENTAL,
HEALTH, AND SAFETY ASPECTS 32 2.5. AREA MANAGER OF WAREHOUSE AND
INVENTORY CONTROL 32 2.5.1. RESPONSIBILITIES 32 2.6. RELIABILITY
ENGINEER 33 2.6.1. RESPONSIBILITIES 34 2.6.2. JOB SKILLS 34 2.6.3.
RELIABILITY ENGINEERING DASHBOARD*KEY PERFORMANCE INDICATORS 35 VII VIII
CONTENTS C H A P T E R 3 PREVENTIVE MAINTENANCE PROGRAM 3.1.
RELIABILITY-BASED PREVENTIVE MAINTENANCE 37 3.1.1. INFORMATION
COLLECTION 38 3.1.2. SYSTEM ANALYSIS 38 3.1.3. IDENTIFICATION OF SYSTEMS
38 3.1.4. IDENTIFICATION OF SYSTEM FUNCTIONS 38 3.1.5. SELECTION OF
SYSTEMS 38 3.1.6. SYSTEM FUNCTIONAL FAILURE AND CRITICALITY RATING 40
3.2. IDENTIFICATION OF FUNCTIONALLY SIGNIFICANT ITEMS 40 3.3.
MAINTENANCE TASK SELECTION (DECISION LOGIC TREE ANALYSIS) 40 3.3.1.
LEVELS OF ANALYSIS 41 3.3.2. PARALLELING AND DEFAULT LOGIC 43 3.4.
MAINTENANCE TASKS 43 3.5. TASK FREQUENCIES/INTERVALS 44 C H A P T E E 4
PREDICTIVE MAINTENANCE PROGRAM 4.1. SETTING UP A PREVENTIVE/PREDICTIVE
MAINTENANCE PROGRAM 49 4.2. VISUAL INSPECTION 50 4.3. VIBRATION ANALYSIS
50 4.4. THERMOGRAPHY 53 4.5. TRIBOLOGY 54 4.6. ULTRASONICS 56 C H A P T
E R 5 RELIABILITY PROCESSES 5.1. RELIABILITY SOFTWARE*MANAGING THE
HEALTH OF ASSETS 57 5.1.1. BUILDING AN EFFECTIVE ASSET RELIABILITY
PROGRAM 58 5.1.2. USING RELIABILITY SOFTWARE TO PUT THE PROGRAM INTO
ACTION 58 5.1.3. USING HANDHELD DEVICES TO COLLECT AND UPLOAD CONDITION
INSPECTION DATA 59 5.1.4. PLOTTING ASSET HEALTH TRENDS 61 5.1.5.
CAPTURING THE EXPERTS KNOWLEDGE ABOUT ASSET CONDITION 61 5.1.6.
INTEGRATION TO ENTERPRISE ASSET MANAGEMENT AND COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS 62 5.1.7. THE BOTTOM LINE 63 5.2. SEVEN QUESTIONS
ADDRESSED BY RELIABILITY CENTERED MAINTENANCE 63 5.3. FAILURE MODE AND
EFFECTS ANALYSIS 66 5.4. EQUIPMENT CRITICALITY ANALYSIS 68 5.4.1.
PREPARING FOR AN EQUIPMENT CRITICALITY ANALYSIS 71 5.4.2. CONDUCTING THE
REVIEW 72 5.4.3. ANALYZING THE ASSESSMENT RESULTS 75 5.4.4. USING THE
OUTPUT OF THE EQUIPMENT CRITICALITY ASSESSMENT 77 5.4.5. CONCLUSIONS 78
5.5. ROOT CAUSE ANALYSIS 79 5.5.1. PLAN 79 5.5.2. DO 81 5.5.3. CHECK 83
5.5.4. ACT 86 C H A P T E R 6 KEY PERFORMANCE INDICATORS 6.1. DEFINING
AND UNDERSTANDING KPIS 89 6.1.1. THE PROBLEM 90 6.1.2. JOHNDAY 91 6.1.3.
THE SOLUTION 93 6.2. KPI DASHBOARDS 93 6.2.1. PLANT MANAGER DASHBOARD 93
6.2.2. PLANT MANAGEMENT TEAM DASHBOARD 93 6.2.3. PRODUCTION MANAGER
(SUPERVISOR) DASHBOARD 94 6.2.4. PRODUCTION OPERATOR DASHBOARD 94 6.2.5.
MAINTENANCE MANAGER (SUPERVISOR) DASHBOARD 94 6.2.6. MAINTENANCE STAFF
DASHBOARD 95 6.2.7. RELIABILITY ENGINEER DASHBOARD 95 6.2.8. ENGINEERING
MANAGER DASHBOARD 95 6.2.9. PURCHASING MANAGER DASHBOARD 95 6.2.10.
MAINTENANCE STORES MANAGER 95 6.2.11. CONCLUSION 95 CONTENTS IX 6.3.
MEASURING AND MANAGING THE MAINTENANCE FUNCTION 95 6.3.1. PHYSICAL ASSET
MANAGEMENT 96 6.3.2. THE ASSET RELIABILITY PROCESS 97 6.3.3. PERFORMANCE
METRICS FOR THE MAINTENANCE FUNCTION 99 6.3.4. RELIABILITY PROCESS KEY
PERFORMANCE INDICATORS*LEADING MEASURES 99 6.3.5. WORK IDENTIFICATION 99
6.3.6. WORKPLANNING 100 6.3.7. WORK SCHEDULING 100 6.3.8. WORK EXECUTION
101 6.3.9. FOLLOW-UP 101 6.3.10. PERFORMANCE ANALYSIS 101 6.3.11. KEY
PERFORMANCE INDICATORS OF MAINTENANCE EFFECTIVENESS (RESULT MEASURES)
102 6.3.12. THE IMPORTANCE OF THE WORK ORDER 103 6.3.13. REPORTING AND
USE OF KEY PERFORMANCE INDICATORS 103 6.3.14. CONCLUSION 104 C H A F T E
R P A R T II EQUIPMENT AND PROCESSES C H A P T E R 8 CHAIN DRIVES CHAIN
SELECTION 124 8.1.1. PIAIN OR DETACHABLE-LINK CHAIN 124 8.1.2. ROLLER
CHAIN 124 8.1.3. SPROCKETS 124 CHAIN INSTALLATION 124 POWER TRAIN
FORMULAS 125 8.3.1. SHAFT SPEED 125 CHAIN LENGTH 126 MULTIPLE SPROCKETS
126 6. CHAIN SPEED 127 7. PREVENTIVE MAINTENANCE PROCEDURES 127 C H A P
T E R TOTAL PRODUCTIVE MAINTENANCE 7.1. INTRODUCTION TO TOTAL PRODUCTIVE
MAINTENANCE 107 7.1.1. THE TPM ORGANIZATION 107 7.1.2. TPM OBJECTIVES
108 7.1.3. AUTONOMOUS MAINTENANCE 108 7.1.4. EQUIPMENT MANAGEMENT 108
7.1.5. TPM INTEGRATION 108 7.1.6. TPM IS AN INVESTMENT 108 7.1.7.
CALCULATING MAJOR LOSSES IS KEY TO TPM S SUCCESS 109 7.2. LEAN
RELIABILITY 111 7.2.1. THE EVOLUTION FROM LEAN MANUFACTURING TO LEAN
MAINTENANCE TO LEAN RELIABILITY 111 7.2.2. MANAGING ASSET PERFORMANCE TO
MEET CUSTOMER NEEDS 112 7.2.3. THE BASIC PRINCIPLES OF LEAN RELIABILITY
114 7.2.4. HOW LEAN RELIABILITY ALIGNS WITH TPM, KAIZEN, FIVE S, AND SIX
SIGMA 117 7.2.5. KEY ELEMENTS TO IMPLEMENT AND SUSTAIN LEAN RELIABILITY
119 7.2.6. SUMMARY 120 9 HYDRAULICS 9.1. HYDRAULIC KNOWLEDGE 129 9.2.
HYDRAULIC TROUBLESHOOTER 129 9.3. GENERAL MAINTENANCE PERSON 129 9.4.
BEST MAINTENANCE HYDRAULIC REPAIR PRACTICES 130 9.5. ROOT CAUSE FAILURE
ANALYSIS 130 9.6. PREVENTIVE MAINTENANCE 130 9.7. MEASURING SUCCESS 132
9.8. RECOMMENDED MAINTENANCE MODIFICATIONS 133 C H A P T E R 10
MAINTENANCE WELDING 10.1. SHIELDED METAL ARE WELDING (SMAW), STICK
WELDING 136 10.2. FLUX-CORED ARE WELDING (FCAW) 137 10.2.1. FCAW WITH
GAS 137 10.2.2. FCAW SELF-SHIELDED 137 10.3. GAS-SHIELDED METAL ARE
WELDING (GMAW) 141 X CONTENTS 10.3.1. GMAW FOR MAINTENANCE WELDING 141
10.3.2. GAS SELECTION FOR GMAW 141 10.4. GAS TUNGSTEN ARE WELDING (GTAW)
144 10.4.1. APPLICABILITY OF GTAW 145 10.4.2. ADVANTAGES AND
DISADVANTAGES OF GTAW 145 10.4.3. PRINCIPLES OF OPERATING GTAW 145
10.4.4. POLARITY AND GTAW 147 10.4.5. GTAW SHIELDING GASES AND FLOW
RATES 147 10.4.6. ELECTRODE MATERIAL FOR GTAW 148 10.4.7. GTAW ELECTRODE
SIZE AND TIP SHAPE 148 10.4.8. GTAW ELECTRODE HOLDERS AND GAS NOZZLES
149 10.4.9. CHARACTERISTICS OF GTAW POWER SUPPLIES 149 10.4.10.
GTAWTORCHES 150 10.4.11. MANUAL GTAW TECHNIQUES 151 10.4.12.
ESTABLISHING WELDING PARAMETERS FOR GTAW 151 10.4.13. GAS TUNGSTEN ARE
STARTING METHODS 151 10.5. OXYACETYLENE CUTTING 151 10.6. AIR-CARBON ARE
CUTTING AND GOUGING 152 10.6.1. APPLICATIONS 153 10.6.2. POWER SOURCES
154 10.7. PLASMA ARE CUTTING 155 10.8. WELDING PROCEDURES 157 10.9.
QUALIFICATION OF WEIDERS 157 10.10. PLASMA ARE WELDING 157 10.11. BASE
METALS 157 10.11.1. THE CARBON STEELS 157 10.11.2. THE ALLOY STEELS 158
10.11.3. THE NONFERROUS METALS 160 10.12. CONTROL OF DISTORTION 160
10.13. SPECIAL APPLICATIONS 161 10.13.1. SHEET METAL WELDING 161
10.13.2. HARD SURFACING 161 10.13.3. RESISTING ABRASIVE WEAR 161
10.13.4. RESISTING IMPACT WEAR 161 10.13.5. TYPES OF SURFACING
ELECTRODES 163 10.13.6. CHOOSING HARD-FACING MATERIAL 163 10.13.7. CHECK
WELDING PROCEDURE 165 10.13.8. CHECK BEFORE THE PART IS COMPLETELY WORN
165 10.13.9. HARD SURFACING WITH SAW 165 10.14. SELECTION AND
MAINTENANCE OF EQUIPMENT 167 10.14.1. MACHINES 167 10.14.2. ACCESSORY
EQUIPMENT 169 10.15. INSTALLATION OF EQUIPMENT 169 10.16. EQUIPMENT
OPERATION AND MAINTENANCE 170 10.16.1. KEEP THE MACHINE CLEAN AND COOL
170 10.16.2. DO NOT ABUSE THE MACHINE 170 10.16.3. 10.16.4. 10.16.5.
10.17. SAFETY DO NOT WORK THE MACHINE OVER ITS RATED CAPACITY 170 DO NOT
HANDLE ROUGHLY 170 MAINTAIN THE MACHINE REGULAER LY 170 172 C H A F I E E
11 BEARINGS 11.1. TYPES OF MOVEMENT 175 11.1.1. ABOUT A POINT
(ROTATIONAL) 175 11.1.2. ABOUT A LINE (ROTATIONAL) 175 11.1.3. ALONG A
LINE (TRANSLATIONAL) 175 11.1.4. IN A PLANE (ROTATIONAL/ TRANSLATIONAL)
178 11.2. COMMONLY USED BEARING TYPES 178 11.2.1. PIAIN BEARINGS 178
11.2.2. ROLLING ELEMENT OR ANTIFRICTION 182 11.2.3. ROLLER 185 11.3.
BEARING MATERIALS 187 11.3.1. PIAIN 188 11.3.2. ROLLING ELEMENT 188
11.4. LUBRICATION 188 11.4.1. PIAIN BEARINGS 188 11.4.2. ROLLING ELEMENT
BEARINGS 189 11.5. INSTALLATION AND GENERAL HANDLING PRECAUTIONS 190
11.5.1. PIAIN BEARING INSTALLATION 190 11.5.2. ROLLER BEARING
INSTALLATION 190 11.5.3. GENERAL ROLLER-ELEMENT BEARING HANDLING
PRECAUTIONS 192 11.6. BEARING FAILURES, DEFICIENCIES, AND THEIR CAUSES
193 11.6.1. IMPROPER BEARING SELECTION AND/OR INSTALLATION 193 CHAPTER
12 COMPRESSORS 12.1. CENTRIFUGAL 199 12.1.1. CONFIGURATION 199 12.2.
PERFORMANCE 201 12.2.1. FIRST LAW OF THERMODYNAMICS 201 12.2.2. SECOND
LAW OF THERMODYNAMICS 202 12.2.3. PRESSURE/VOLUME/TEMPERATURE (PVT)
RELATIONSHIP 202 CONTENTS XI 12.2.4. PRESSURE/COMPRESSION 202 12.2.5.
OTHER PERFORMANCE INDICATORS 202 12.3. POSITIVE DISPLACEMENT 203 12.3.1.
ROTARY 203 12.4. RECIPROCATING 206 12.4.1. CONFIGURATION 207 12.4.2.
PERFORMANCE 210 12.4.3. INSTALLATION 210 12.4.4. OPERATING METHODS 212
12.5. TROUBLESHOOTING 212 12.5.1. CENTRIFUGAL 212 12.5.2. ROTARY-TYPE,
POSITIVE DISPLACEMENT 212 12.5.3. RECIPROCATING, POSITIVE DISPLACEMENT
216 C H A P T E R 13 GEARS AND GEARBOXES 13.1. SPUR GEARS 225 13.2.
PITCH DIAMETER AND CENTER DISTANCE 226 13.3. CIRCULAR PITCH 227 13.4.
DIAMETRICAL PITCH AND MEASUREMENT 227 13.4.1. METHOD 1 228 13.4.2.
METHOD 2 228 13.5. PITCH CALCULATIONS 228 13.6. TOOTH PROPORTIONS 229
13.7. BACKLASH 230 13.8. OTHER GEAR TYPES 230 13.8.1. BEVEL AND MITER
230 13.8.2. HELICAL 231 13.8.3. WORM 232 13.8.4. HERRINGBONE 233 13.8.5.
GEAR DYNAMICS AND FAILURE MODES 233 13.8.6. COMMON CHARACTERISTICS 235
13.9. TROUBLESHOOTING 236 13.9.1. NORMAL WEAR 237 13.9.2. ABNORMAL WEAR
237 C H A P T E R 14 PACKING AND SEALS 14.1. FUNDAMENTALS 239 14.1.1.
SHAFT SEAL REQUIREMENTS 239 14.1.2. SEALING DEVICES 239 14.2. MECHANICAL
SEAL DESIGNS 242 14.2.1. SINGLE-COIL SPRING SEAL 242 14.2.2. POSITIVE
DRIVE 242 14.3. INSTALLATION PROCEDURES 242 14.3.1. PACKED STUFFING BOX
243 14.3.2. MECHANICAL SEALS 245 14.4. TROUBLESHOOTING 248 14.4.1.
MECHANICAL SEALS 248 14.4.2. PACKED BOXES 249 C H A P T E R 15 ELECTRIC
MOTORS 15.1. BEARING FREQUENCIES 251 15.2. IMBALANCE 251 15.3. LINE
FREQUENCY 251 15.4. LOOSE ROTOR BARS 251 15.5. RUNNING SPEED 252 15.6.
SLIP FREQUENCY 252 15.7. V-BELT INTERMEDIATE DRIVES 252 15.8. ELECTRIC
MOTOR ANALYSIS 252 P A R T III ADDITIONAL READINGS ON MAINTENANCE AND
RELIABILITY C H A P T E R 16 RELIABILITY ARTICLES 16.1. TOP FIVE REASONS
WHY COMPANIES DON T MEASURE RELIABILITY: IT SEEMS LIKE EVERYONE HAS AN
EXCUSE AS TO WHY THEY DON T MEASURE RELIABILITY 255 16.1.1. REASONL 255
16.1.2. REASON2 255 16.1.3. REASON3 255 16.1.4. REASON4 255 16.1.5.
REASON5 256 16.2. 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 256 XII
CONTENTS 16.3. EXTERMINATE LUBE PROBLEMS: GREASE AND OIL EXPERTISE CAN
BE A SERIOUS COMPETITIVE EDGE 257 16.3.1. BIG, BAD, AND UGLY 257 16.3.2.
MAKE LUBE EXPERTISE A SPECIALTY 258 16.3.3. GET THE JOB DONE 260 16.4.
WHAT IT TAKES TO MAKE THE CLIMB FROM REACTIVE TO RCM 260 16.4.1. WAVING
THE FLAG 261 16.4.2. DOES MANAGEMENT UNDERSTAND? 269 16.4.3. WHO OWNS
RELIABILITY? 270 16.4.4. INFORMAL VERSUS FORMAL PM PROGRAMS 270 16.4.5.
TO MEASURE IS TO MANAGE 270 16.4.6. DEPTH OF UNDERSTANDING 271 16.4.7.
INDICATED ACTIONS 272 16.4.8. LESSONS ARE SIMPLE 273 16.5. PUT A
PLANT-WIDE FOCUS ON FUNCTIONAL FAILURES 274 16.6. 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 FAMILIAER
WITH THE DEFINITION OF RELIABILITY 275 16.7. WHEN PREVENTIVE MAINTENANCE
DOESN T WORK 276 16.8. THE TOP FOUR REASONS WHY PREDICTIVE MAINTENANCE
FAILS AND WHAT TO DO ABOUT IT 277 16.8.1. PFCURVE 278 16.8.2. REASON
1: THE COLLECTION OF PDM DATA IS NOT VIEWED AS PART OF THE TOTAL
MAINTENANCE PROCESS 278 16.8.3. REASON 2: THE COLLECTED PDM DATA ARRIVES
TOO LATE TO PREVENT EQUIPMENT FAILURES 279 16.8.4. REASON 3: MANY
COMPANIES FAIL TO TAKE ADVANTAGE OF DATA FROM PLCS AND DCSS 279 16.8.5.
REASON 4: MOST PDM DATA IS DISPERSED IN TOO MANY NON-INTEGRATED
DATABASES 280 16.8.6. SOME SIMPLE GUIDELINES WILL HELP TO GET YOU MOVING
IN THE RIGHT DIRECTION 281 16.8.7. SUMMARY 282 C H A P T E R 17 MTBF
USERS GUIDE 17.1. UNDERSTANDING DEFINITIONS 283 17.2. THE MTBF PROCESS
283 17.3. EXAMPLE 284 17.3.1. MTBF PERCENTAGE CHANGE 284 17.3.2. TOTAL
PLANT MTBF 284 17.4. SUMMARY 284 A P P E N D I X AE WORKFLOW FOR PLANNING
A P P E N D I X B CHECKLISTS AND FORMS GLOSSARY 315 INDEX 319
|
| adam_txt |
RULES OF THUMB F OR MAINTENANCE AND RELIABILITY ENGINEERS RICKY SMITH R.
KEITH MOBLEY AMSTERDAM * BOSTON * HEIDELBERG * LONDON NEW YORK * OXFORD
* PARIS * SAN DIEGO SAN FRANCISCO * SINGAPORE * SYDNEY * TOKYO ELSEVTER
BUTTERWORTH-HEINEMANN IS AN IMPRINT OF ELSEVIER CONTENTS
INTRODUCTION*THE RECOMMENDED FIRST STEP TO RULES OF THUMB IN RELIABILITY
ENGINEERING XIII P A R T I THE BASICS OF MAINTENANCE AND RELIABILITY
1.5. INTRODUCTION TO CHANGE MANAGEMENT 14 1.6. DEVELOPING A BUSINESS
CASE FOR A RELIABILITY INITIATIVE 16 1.7. CALCULATING RETURN ON
INVESTMENT 19 1.7.1. LEADERSHIP OF THE ROI TEAM 19 1.7.2. CASE STUDY 19
1.8. PLANNING AND SCHEDULING 21 C H A P T E R C H A P T E R
UNDERSTANDING MAINTENANCE AND RELIABILITY 1.1. THE MAINTENANCE FUNCTION
3 1.2. STRATEGY TO ACHIEVE WORLD-CLASS PRODUCTION THROUGH RELIABILITY 3
1.2.1. MAINTENANCE APPROACHES 4 1.2.2. MAINTENANCE MANAGEMENT PHILOSOPHY
4 1.2.3. THE FUNCTION AND CONTROL SYSTEM 5 1.2.4. WHAT IS MAINTENANCE? 5
1.2.5. SPECIFICATION 6 1.2.6. THE MAINTENANCE FUNCTION 6 1.3. WHAT IS
RELIABILITY? 8 1.3.1. COMPANIES THAT GET IT 8 1.3.2. WHY MOVE TOWARD
PROACTIVE WORK? 9 1.3.3. A NEW WAY TO VIEW FAILURE 10 1.4.
MAINTENANCE/RELIABILITY ASSESSMENT 10 THE FUNCTIONAL MAINTENANCE
ORGANIZATION AND ITS PEOPLE 2.1. FUNCTIONAL MAINTENANCE ORGANIZATIONAL
STRUCTURE 27 2.2. MAINTENANCE SUPERVISOR 29 2.2.1. RESPONSIBILITIES 29
2.2.2. ENVIRONMENTAL, HEALTH, AND SAFETY ASPECTS 30 2.3. MAINTENANCE
PLANNER/SCHEDULER 30 2.3.1. RESPONSIBILITIES 30 2.4. MAINTENANCE AND
ENGINEERING MANAGER 31 2.4.1. RESPONSIBILITIES 31 2.4.2. ENVIRONMENTAL,
HEALTH, AND SAFETY ASPECTS 32 2.5. AREA MANAGER OF WAREHOUSE AND
INVENTORY CONTROL 32 2.5.1. RESPONSIBILITIES 32 2.6. RELIABILITY
ENGINEER 33 2.6.1. RESPONSIBILITIES 34 2.6.2. JOB SKILLS 34 2.6.3.
RELIABILITY ENGINEERING DASHBOARD*KEY PERFORMANCE INDICATORS 35 VII VIII
CONTENTS C H A P T E R 3 PREVENTIVE MAINTENANCE PROGRAM 3.1.
RELIABILITY-BASED PREVENTIVE MAINTENANCE 37 3.1.1. INFORMATION
COLLECTION 38 3.1.2. SYSTEM ANALYSIS 38 3.1.3. IDENTIFICATION OF SYSTEMS
38 3.1.4. IDENTIFICATION OF SYSTEM FUNCTIONS 38 3.1.5. SELECTION OF
SYSTEMS 38 3.1.6. SYSTEM FUNCTIONAL FAILURE AND CRITICALITY RATING 40
3.2. IDENTIFICATION OF FUNCTIONALLY SIGNIFICANT ITEMS 40 3.3.
MAINTENANCE TASK SELECTION (DECISION LOGIC TREE ANALYSIS) 40 3.3.1.
LEVELS OF ANALYSIS 41 3.3.2. PARALLELING AND DEFAULT LOGIC 43 3.4.
MAINTENANCE TASKS 43 3.5. TASK FREQUENCIES/INTERVALS 44 C H A P T E E 4
PREDICTIVE MAINTENANCE PROGRAM 4.1. SETTING UP A PREVENTIVE/PREDICTIVE
MAINTENANCE PROGRAM 49 4.2. VISUAL INSPECTION 50 4.3. VIBRATION ANALYSIS
50 4.4. THERMOGRAPHY 53 4.5. TRIBOLOGY 54 4.6. ULTRASONICS 56 C H A P T
E R 5 RELIABILITY PROCESSES 5.1. RELIABILITY SOFTWARE*MANAGING THE
HEALTH OF ASSETS 57 5.1.1. BUILDING AN EFFECTIVE ASSET RELIABILITY
PROGRAM 58 5.1.2. USING RELIABILITY SOFTWARE TO PUT THE PROGRAM INTO
ACTION 58 5.1.3. USING HANDHELD DEVICES TO COLLECT AND UPLOAD CONDITION
INSPECTION DATA 59 5.1.4. PLOTTING ASSET HEALTH TRENDS 61 5.1.5.
CAPTURING THE EXPERTS' KNOWLEDGE ABOUT ASSET CONDITION 61 5.1.6.
INTEGRATION TO ENTERPRISE ASSET MANAGEMENT AND COMPUTERIZED MAINTENANCE
MANAGEMENT SYSTEMS 62 5.1.7. THE BOTTOM LINE 63 5.2. SEVEN QUESTIONS
ADDRESSED BY RELIABILITY CENTERED MAINTENANCE 63 5.3. FAILURE MODE AND
EFFECTS ANALYSIS 66 5.4. EQUIPMENT CRITICALITY ANALYSIS 68 5.4.1.
PREPARING FOR AN EQUIPMENT CRITICALITY ANALYSIS 71 5.4.2. CONDUCTING THE
REVIEW 72 5.4.3. ANALYZING THE ASSESSMENT RESULTS 75 5.4.4. USING THE
OUTPUT OF THE EQUIPMENT CRITICALITY ASSESSMENT 77 5.4.5. CONCLUSIONS 78
5.5. ROOT CAUSE ANALYSIS 79 5.5.1. PLAN 79 5.5.2. DO 81 5.5.3. CHECK 83
5.5.4. ACT 86 C H A P T E R 6 KEY PERFORMANCE INDICATORS 6.1. DEFINING
AND UNDERSTANDING KPIS 89 6.1.1. THE PROBLEM 90 6.1.2. JOHNDAY 91 6.1.3.
THE SOLUTION 93 6.2. KPI DASHBOARDS 93 6.2.1. PLANT MANAGER DASHBOARD 93
6.2.2. PLANT MANAGEMENT TEAM DASHBOARD 93 6.2.3. PRODUCTION MANAGER
(SUPERVISOR) DASHBOARD 94 6.2.4. PRODUCTION OPERATOR DASHBOARD 94 6.2.5.
MAINTENANCE MANAGER (SUPERVISOR) DASHBOARD 94 6.2.6. MAINTENANCE STAFF
DASHBOARD 95 6.2.7. RELIABILITY ENGINEER DASHBOARD 95 6.2.8. ENGINEERING
MANAGER DASHBOARD 95 6.2.9. PURCHASING MANAGER DASHBOARD 95 6.2.10.
MAINTENANCE STORES MANAGER 95 6.2.11. CONCLUSION 95 CONTENTS IX 6.3.
MEASURING AND MANAGING THE MAINTENANCE FUNCTION 95 6.3.1. PHYSICAL ASSET
MANAGEMENT 96 6.3.2. THE ASSET RELIABILITY PROCESS 97 6.3.3. PERFORMANCE
METRICS FOR THE MAINTENANCE FUNCTION 99 6.3.4. RELIABILITY PROCESS KEY
PERFORMANCE INDICATORS*LEADING MEASURES 99 6.3.5. WORK IDENTIFICATION 99
6.3.6. WORKPLANNING 100 6.3.7. WORK SCHEDULING 100 6.3.8. WORK EXECUTION
101 6.3.9. FOLLOW-UP 101 6.3.10. PERFORMANCE ANALYSIS 101 6.3.11. KEY
PERFORMANCE INDICATORS OF MAINTENANCE EFFECTIVENESS (RESULT MEASURES)
102 6.3.12. THE IMPORTANCE OF THE WORK ORDER 103 6.3.13. REPORTING AND
USE OF KEY PERFORMANCE INDICATORS 103 6.3.14. CONCLUSION 104 C H A F T E
R P A R T II EQUIPMENT AND PROCESSES C H A P T E R 8 CHAIN DRIVES CHAIN
SELECTION 124 8.1.1. PIAIN OR DETACHABLE-LINK CHAIN 124 8.1.2. ROLLER
CHAIN 124 8.1.3. SPROCKETS 124 CHAIN INSTALLATION 124 POWER TRAIN
FORMULAS 125 8.3.1. SHAFT SPEED 125 CHAIN LENGTH 126 MULTIPLE SPROCKETS
126 6. CHAIN SPEED 127 7. PREVENTIVE MAINTENANCE PROCEDURES 127 C H A P
T E R TOTAL PRODUCTIVE MAINTENANCE 7.1. INTRODUCTION TO TOTAL PRODUCTIVE
MAINTENANCE 107 7.1.1. THE TPM ORGANIZATION 107 7.1.2. TPM OBJECTIVES
108 7.1.3. AUTONOMOUS MAINTENANCE 108 7.1.4. EQUIPMENT MANAGEMENT 108
7.1.5. TPM INTEGRATION 108 7.1.6. TPM IS AN INVESTMENT 108 7.1.7.
CALCULATING MAJOR LOSSES IS KEY TO TPM'S SUCCESS 109 7.2. LEAN
RELIABILITY 111 7.2.1. THE EVOLUTION FROM LEAN MANUFACTURING TO LEAN
MAINTENANCE TO LEAN RELIABILITY 111 7.2.2. MANAGING ASSET PERFORMANCE TO
MEET CUSTOMER NEEDS 112 7.2.3. THE BASIC PRINCIPLES OF LEAN RELIABILITY
114 7.2.4. HOW LEAN RELIABILITY ALIGNS WITH TPM, KAIZEN, FIVE S, AND SIX
SIGMA 117 7.2.5. KEY ELEMENTS TO IMPLEMENT AND SUSTAIN LEAN RELIABILITY
119 7.2.6. SUMMARY 120 9 HYDRAULICS 9.1. HYDRAULIC KNOWLEDGE 129 9.2.
HYDRAULIC TROUBLESHOOTER 129 9.3. GENERAL MAINTENANCE PERSON 129 9.4.
BEST MAINTENANCE HYDRAULIC REPAIR PRACTICES 130 9.5. ROOT CAUSE FAILURE
ANALYSIS 130 9.6. PREVENTIVE MAINTENANCE 130 9.7. MEASURING SUCCESS 132
9.8. RECOMMENDED MAINTENANCE MODIFICATIONS 133 C H A P T E R 10
MAINTENANCE WELDING 10.1. SHIELDED METAL ARE WELDING (SMAW), "STICK
WELDING" 136 10.2. FLUX-CORED ARE WELDING (FCAW) 137 10.2.1. FCAW WITH
GAS 137 10.2.2. FCAW SELF-SHIELDED 137 10.3. GAS-SHIELDED METAL ARE
WELDING (GMAW) 141 X CONTENTS 10.3.1. GMAW FOR MAINTENANCE WELDING 141
10.3.2. GAS SELECTION FOR GMAW 141 10.4. GAS TUNGSTEN ARE WELDING (GTAW)
144 10.4.1. APPLICABILITY OF GTAW 145 10.4.2. ADVANTAGES AND
DISADVANTAGES OF GTAW 145 10.4.3. PRINCIPLES OF OPERATING GTAW 145
10.4.4. POLARITY AND GTAW 147 10.4.5. GTAW SHIELDING GASES AND FLOW
RATES 147 10.4.6. ELECTRODE MATERIAL FOR GTAW 148 10.4.7. GTAW ELECTRODE
SIZE AND TIP SHAPE 148 10.4.8. GTAW ELECTRODE HOLDERS AND GAS NOZZLES
149 10.4.9. CHARACTERISTICS OF GTAW POWER SUPPLIES 149 10.4.10.
GTAWTORCHES 150 10.4.11. MANUAL GTAW TECHNIQUES 151 10.4.12.
ESTABLISHING WELDING PARAMETERS FOR GTAW 151 10.4.13. GAS TUNGSTEN ARE
STARTING METHODS 151 10.5. OXYACETYLENE CUTTING 151 10.6. AIR-CARBON ARE
CUTTING AND GOUGING 152 10.6.1. APPLICATIONS 153 10.6.2. POWER SOURCES
154 10.7. PLASMA ARE CUTTING 155 10.8. WELDING PROCEDURES 157 10.9.
QUALIFICATION OF WEIDERS 157 10.10. PLASMA ARE WELDING 157 10.11. BASE
METALS 157 10.11.1. THE CARBON STEELS 157 10.11.2. THE ALLOY STEELS 158
10.11.3. THE NONFERROUS METALS 160 10.12. CONTROL OF DISTORTION 160
10.13. SPECIAL APPLICATIONS 161 10.13.1. SHEET METAL WELDING 161
10.13.2. HARD SURFACING 161 10.13.3. RESISTING ABRASIVE WEAR 161
10.13.4. RESISTING IMPACT WEAR 161 10.13.5. TYPES OF SURFACING
ELECTRODES 163 10.13.6. CHOOSING HARD-FACING MATERIAL 163 10.13.7. CHECK
WELDING PROCEDURE 165 10.13.8. CHECK BEFORE THE PART IS COMPLETELY WORN
165 10.13.9. HARD SURFACING WITH SAW 165 10.14. SELECTION AND
MAINTENANCE OF EQUIPMENT 167 10.14.1. MACHINES 167 10.14.2. ACCESSORY
EQUIPMENT 169 10.15. INSTALLATION OF EQUIPMENT 169 10.16. EQUIPMENT
OPERATION AND MAINTENANCE 170 10.16.1. KEEP THE MACHINE CLEAN AND COOL
170 10.16.2. DO NOT ABUSE THE MACHINE 170 10.16.3. 10.16.4. 10.16.5.
10.17. SAFETY DO NOT WORK THE MACHINE OVER ITS RATED CAPACITY 170 DO NOT
HANDLE ROUGHLY 170 MAINTAIN THE MACHINE REGULAER LY 170 172 C H A F I E E
11 BEARINGS 11.1. TYPES OF MOVEMENT 175 11.1.1. ABOUT A POINT
(ROTATIONAL) 175 11.1.2. ABOUT A LINE (ROTATIONAL) 175 11.1.3. ALONG A
LINE (TRANSLATIONAL) 175 11.1.4. IN A PLANE (ROTATIONAL/ TRANSLATIONAL)
178 11.2. COMMONLY USED BEARING TYPES 178 11.2.1. PIAIN BEARINGS 178
11.2.2. ROLLING ELEMENT OR ANTIFRICTION 182 11.2.3. ROLLER 185 11.3.
BEARING MATERIALS 187 11.3.1. PIAIN 188 11.3.2. ROLLING ELEMENT 188
11.4. LUBRICATION 188 11.4.1. PIAIN BEARINGS 188 11.4.2. ROLLING ELEMENT
BEARINGS 189 11.5. INSTALLATION AND GENERAL HANDLING PRECAUTIONS 190
11.5.1. PIAIN BEARING INSTALLATION 190 11.5.2. ROLLER BEARING
INSTALLATION 190 11.5.3. GENERAL ROLLER-ELEMENT BEARING HANDLING
PRECAUTIONS 192 11.6. BEARING FAILURES, DEFICIENCIES, AND THEIR CAUSES
193 11.6.1. IMPROPER BEARING SELECTION AND/OR INSTALLATION 193 CHAPTER
12 COMPRESSORS 12.1. CENTRIFUGAL 199 12.1.1. CONFIGURATION 199 12.2.
PERFORMANCE 201 12.2.1. FIRST LAW OF THERMODYNAMICS 201 12.2.2. SECOND
LAW OF THERMODYNAMICS 202 12.2.3. PRESSURE/VOLUME/TEMPERATURE (PVT)
RELATIONSHIP 202 CONTENTS XI 12.2.4. PRESSURE/COMPRESSION 202 12.2.5.
OTHER PERFORMANCE INDICATORS 202 12.3. POSITIVE DISPLACEMENT 203 12.3.1.
ROTARY 203 12.4. RECIPROCATING 206 12.4.1. CONFIGURATION 207 12.4.2.
PERFORMANCE 210 12.4.3. INSTALLATION 210 12.4.4. OPERATING METHODS 212
12.5. TROUBLESHOOTING 212 12.5.1. CENTRIFUGAL 212 12.5.2. ROTARY-TYPE,
POSITIVE DISPLACEMENT 212 12.5.3. RECIPROCATING, POSITIVE DISPLACEMENT
216 C H A P T E R 13 GEARS AND GEARBOXES 13.1. SPUR GEARS 225 13.2.
PITCH DIAMETER AND CENTER DISTANCE 226 13.3. CIRCULAR PITCH 227 13.4.
DIAMETRICAL PITCH AND MEASUREMENT 227 13.4.1. METHOD 1 228 13.4.2.
METHOD 2 228 13.5. PITCH CALCULATIONS 228 13.6. TOOTH PROPORTIONS 229
13.7. BACKLASH 230 13.8. OTHER GEAR TYPES 230 13.8.1. BEVEL AND MITER
230 13.8.2. HELICAL 231 13.8.3. WORM 232 13.8.4. HERRINGBONE 233 13.8.5.
GEAR DYNAMICS AND FAILURE MODES 233 13.8.6. COMMON CHARACTERISTICS 235
13.9. TROUBLESHOOTING 236 13.9.1. NORMAL WEAR 237 13.9.2. ABNORMAL WEAR
237 C H A P T E R 14 PACKING AND SEALS 14.1. FUNDAMENTALS 239 14.1.1.
SHAFT SEAL REQUIREMENTS 239 14.1.2. SEALING DEVICES 239 14.2. MECHANICAL
SEAL DESIGNS 242 14.2.1. SINGLE-COIL SPRING SEAL 242 14.2.2. POSITIVE
DRIVE 242 14.3. INSTALLATION PROCEDURES 242 14.3.1. PACKED STUFFING BOX
243 14.3.2. MECHANICAL SEALS 245 14.4. TROUBLESHOOTING 248 14.4.1.
MECHANICAL SEALS 248 14.4.2. PACKED BOXES 249 C H A P T E R 15 ELECTRIC
MOTORS 15.1. BEARING FREQUENCIES 251 15.2. IMBALANCE 251 15.3. LINE
FREQUENCY 251 15.4. LOOSE ROTOR BARS 251 15.5. RUNNING SPEED 252 15.6.
SLIP FREQUENCY 252 15.7. V-BELT INTERMEDIATE DRIVES 252 15.8. ELECTRIC
MOTOR ANALYSIS 252 P A R T III ADDITIONAL READINGS ON MAINTENANCE AND
RELIABILITY C H A P T E R 16 RELIABILITY ARTICLES 16.1. TOP FIVE REASONS
WHY COMPANIES DON'T MEASURE RELIABILITY: IT SEEMS LIKE EVERYONE HAS AN
EXCUSE AS TO WHY THEY DON'T MEASURE RELIABILITY 255 16.1.1. REASONL 255
16.1.2. REASON2 255 16.1.3. REASON3 255 16.1.4. REASON4 255 16.1.5.
REASON5 256 16.2. 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 256 XII
CONTENTS 16.3. EXTERMINATE LUBE PROBLEMS: GREASE AND OIL EXPERTISE CAN
BE A SERIOUS COMPETITIVE EDGE 257 16.3.1. BIG, BAD, AND UGLY 257 16.3.2.
MAKE LUBE EXPERTISE A SPECIALTY 258 16.3.3. GET THE JOB DONE 260 16.4.
WHAT IT TAKES TO MAKE THE CLIMB FROM REACTIVE TO RCM 260 16.4.1. WAVING
THE FLAG 261 16.4.2. DOES MANAGEMENT UNDERSTAND? 269 16.4.3. WHO OWNS
RELIABILITY? 270 16.4.4. INFORMAL VERSUS FORMAL PM PROGRAMS 270 16.4.5.
TO MEASURE IS TO MANAGE 270 16.4.6. DEPTH OF UNDERSTANDING 271 16.4.7.
INDICATED ACTIONS 272 16.4.8. LESSONS ARE SIMPLE 273 16.5. PUT A
PLANT-WIDE FOCUS ON FUNCTIONAL FAILURES 274 16.6. 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 FAMILIAER
WITH THE DEFINITION OF RELIABILITY 275 16.7. WHEN PREVENTIVE MAINTENANCE
DOESN'T WORK 276 16.8. THE TOP FOUR REASONS WHY PREDICTIVE MAINTENANCE
FAILS AND "WHAT TO DO ABOUT IT" 277 16.8.1. PFCURVE 278 16.8.2. REASON
1: THE COLLECTION OF PDM DATA IS NOT VIEWED AS PART OF THE TOTAL
MAINTENANCE PROCESS 278 16.8.3. REASON 2: THE COLLECTED PDM DATA ARRIVES
TOO LATE TO PREVENT EQUIPMENT FAILURES 279 16.8.4. REASON 3: MANY
COMPANIES FAIL TO TAKE ADVANTAGE OF DATA FROM PLCS AND DCSS 279 16.8.5.
REASON 4: MOST PDM DATA IS DISPERSED IN TOO MANY NON-INTEGRATED
DATABASES 280 16.8.6. SOME SIMPLE GUIDELINES WILL HELP TO GET YOU MOVING
IN THE RIGHT DIRECTION 281 16.8.7. SUMMARY 282 C H A P T E R 17 MTBF
USERS GUIDE 17.1. UNDERSTANDING DEFINITIONS 283 17.2. THE MTBF PROCESS
283 17.3. EXAMPLE 284 17.3.1. MTBF PERCENTAGE CHANGE 284 17.3.2. TOTAL
PLANT MTBF 284 17.4. SUMMARY 284 A P P E N D I X AE WORKFLOW FOR PLANNING
A P P E N D I X B CHECKLISTS AND FORMS GLOSSARY 315 INDEX 319 |
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| index_date | 2024-07-02T19:03:42Z |
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| language | English |
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| spelling | Smith, Ricky Verfasser aut Rules of thumb for maintenance and reliability engineers Ricky Smith ; R. Keith Mobley Amsterdam [u.a.] Elsevier 2008 XIII, 320 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Fiabilité Güvenilirlik Maintenabilité Sistem mühendisliği - Yönetim Systems engineering Management Reliability Mobley, R. Keith Sonstige oth http://www.loc.gov/catdir/toc/ecip0717/2007019635.html Table of contents only GBV Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016162786&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Smith, Ricky Rules of thumb for maintenance and reliability engineers Fiabilité Güvenilirlik Maintenabilité Sistem mühendisliği - Yönetim Systems engineering Management Reliability |
| title | Rules of thumb for maintenance and reliability engineers |
| title_auth | Rules of thumb for maintenance and reliability engineers |
| title_exact_search | Rules of thumb for maintenance and reliability engineers |
| title_exact_search_txtP | Rules of thumb for maintenance and reliability engineers |
| title_full | Rules of thumb for maintenance and reliability engineers Ricky Smith ; R. Keith Mobley |
| title_fullStr | Rules of thumb for maintenance and reliability engineers Ricky Smith ; R. Keith Mobley |
| title_full_unstemmed | Rules of thumb for maintenance and reliability engineers Ricky Smith ; R. Keith Mobley |
| title_short | Rules of thumb for maintenance and reliability engineers |
| title_sort | rules of thumb for maintenance and reliability engineers |
| topic | Fiabilité Güvenilirlik Maintenabilité Sistem mühendisliği - Yönetim Systems engineering Management Reliability |
| topic_facet | Fiabilité Güvenilirlik Maintenabilité Sistem mühendisliği - Yönetim Systems engineering Management Reliability |
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