Maintenance benchmarking and best practices: a profit- and customer-centered approach
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
New York [u.a.]
McGraw-Hill
2006
|
| Schriftenreihe: | McGraw-Hill maintenance
|
| Schlagworte: | |
| Online-Zugang: | Contributor biographical information Publisher description Table of contents Inhaltsverzeichnis |
| Beschreibung: | XXX, 566 S. Ill., graph. Darst. |
| ISBN: | 0071463399 9780071463393 |
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Datensatz im Suchindex
| _version_ | 1804138897200906240 |
|---|---|
| adam_text | Contents
Preface xv
Acknowledgments xix
Introduction xxi
Part 1 Maximizing Maintenance Best Practices with
a Profit-Centered Approach
Chapter 1. A Profit- and Customer-Centered Maintenance Strategy 3
Maintenance 3
The high cost of gambling with maintenance 3
Profit- and customer-centered contract maintenance 4
Where Is Your Chief Maintenance Officer? 5
Profit ability and leadership 5
A Fundamental Lesson Learned 6
No matter how bad something is, it can always be used as
an illustrative bad example 7
The CMO and PRIDE in Ownership 8
Have You Ever Had Future Shock? 9
Take action on this question 9
Effective In-House Maintenance Plus High-Quality
Maintenance Contractors 10
Where is the profit in maintenance really? 10
Core Requirement versus Core Competencies for Maintenance 13
Neglect of Past Can Be Overcome, Start Your New Millennium Now 13
Chapter 2. Key Requirements for Profit- and Customer-Centered
Maintenance 15
Chapter 3. Four Real Maintenance Challenges We All Face 29
Four Real Maintenance Challenges 29
Lesson learned 31
Billions added to challenge four—commissioning of new
maintenance requirements 32
Challenge One 32
Determining existing maintenance needs 32
V
vi Contents
Challenge Two 33
Challenge Three Is Good News/Bad News 34
But there is some real bad news 34
Challenge Four 34
Another True Lesson Learned 36
Do not gamble, especially with maintenance costs 37
Do not be a takeover target? 39
Part 2 Determining Where You Are as a Profit- and
Customer-Centered Maintenance Operation:
The Scoreboard for Maintenance Excellence
Chapter 4. The Scoreboard for Maintenance Excellence 43
Introduction 43
Understanding the Types of Benchmarking 43
Our Publications Are Free Except? 48
How Do You Get There If You Do Not Know Where There Is
When You Start? 48
Over 24 years of application and evolution 49
Begin with a Very, Very Important First Step 50
Establish a maintenance excellence strategy team 50
How to determine where you are 50
The Scoreboard for Maintenance Excellence 51
Your Global Benchmark 54
Benchmarking results 54
People resources—five benchmark categories 58
Technical skill resources—three benchmark categories 63
The perfect storm: What is the problem? 64
Dealing with the facts 64
What can you do? 65
Physical assets and equipment resources: seven benchmark categories 67
Implementing a Quality Management System (QMS): Consider
Maintenance s Role in Quality Registration 75
Critical Asset Facilitation and Overall Equipment Effectiveness (OEE) 79
Information resources—eight benchmark categories 80
Parts and material resources—two benchmark categories 89
How to Improve Your Maintenance Storeroom 89
Hidden Resource: The Synergy of TEAM Efforts;
Two benchmark Categories 98
Going beyond RCM and TPM 101
The Scoreboard for Excellence 102
A complete Scoreboard assessment is recommended
and so Just Do It! 103
Chapter 5. Guidelines for Conducting a Scoreboard for Maintenance
Excellence Assessment 105
Obtain Leadership Buy-in 105
Step 1: Charter maintenance excellence strategy team 107
Step 2: Understand the evaluation categories and evaluation criteria 107
Contents vii
Step 3: Develop assessment action plan 107
Step 4: Conduct assessment of total maintenance operation 110
Step 5: Analyze, review, and present results 111
Step 6: Develop path forward for maintenance excellence 111
Invest in External Resources 111
Chapter 6. Strategy for Developing a Corporate-Wide Scoreboard 113
Recommended Path Forward Strategy 113
Summary of deliverables to achieve results 117
Typical Project Plan of Action 118
Document assessment results 119
Determine strengths/weaknesses and priorities for action 119
Chapter 7. Case Study: The Scoreboard Self-Assessment:
Just Do It! 121
You Can Just Do It 121
Your personal assignment of baseline points for each benchmark
criterion can be completed right now 121
Once again, outside help is highly recommended, but? 122
How This Training for Maintenance Excellence Event was Conceived 123
Why Training for Maintenance Excellence? 126
Our training capabilities 127
Understanding the true value of maintenance! 128
Customized training for your operation 128
Part 3 Developing Your CMMS as a True Maintenance
Business Management System
Chapter 8. Maximizing the Value of CMMS for Profit-Centered
Maintenance 131
CMMS Justification Is Much More Than Economic Factors 133
A strategy to gain maximum value from CMMS 134
Chapter 9. CMMS Functional Requirements That Support
the Business of Maintenance 141
Functionality—The Important CMMS Features 141
Making the Right CMMS Choice 142
Work order/work management 142
Equipment/asset management 146
Inventory management/MRO materials management 148
Planning and scheduling 153
Preventive maintenance (PM) and predictive maintenance (PdM) 155
Purchasing and MRO procurement 156
Additional CMMS functional capabilities 157
viii Contents
Chapter 10. Case Study: Quantitative and Qualitative Factors
for CMMS Selection 159
The CMMS Selection Process 160
Prepare the vendors 160
Case study: CMMS selection criteria 161
Chapter 11. Maximizing Your IT Investment with the
CMMS Benchmarking System 169
Conducting the CMMS Benchmark Evaluation 170
Summary 185
Understand the Power of CMMS/EAM to Support Potential Savings 185
Use CMMS to Develop Your Maintenance Operation as a Profit Center 186
Chapter 12. Case Study: Effective CMMS Plus Best Practices:
A Powerful Combination for Profit at Argentina s Largest
Steel Maker 189
Part I: Client Overview 189
The challenge 190
The approach 190
The results 191
Part II: Details of the Justification Process for a New CMMS
and Best Practice Implementation 192
Introduction 192
Primary areas of cost justification/savings 193
Part III: The Cost Evaluation Process for SAP R/3 and MAXIMO 201
Introduction 201
Hardware costs 202
Training costs 202
Software costs 202
Cost summary comparison 203
Part 4 The Profit- and Customer-Centered
Maintenance Operation
Chapter 13. Improving Craft Productivity: An Essential
Strategy for Profit and Customer Service 207
Some Definitions of Productivity 207
What is productivity? 209
What is your craft productivity? 210
Should we measure craft productivity? 211
Significant Gained Value Available from Increased Wrench Time 212
Chapter 14. Introducing OCE as a New Buzzword: The Overall
Craft Effectiveness (OCE) Factor 215
Overall Equipment Effectiveness (OEE) 216
OCE focuses upon your craft labor resources 217
Build upon the basics 217
Contents ix
Maintenance excellence can start with PRIDE in maintenance 217
A very important question for the craft workforce 218
Craft Utilization 220
Improve wrench time first 221
Gained value of 10 percent in wrench time 221
Craft Performance 223
Craft performance calculation 223
The ACE Team Benchmarking Process 224
Planning times are essential 225
Craft Service Quality 225
What OCE Can You Expect? 226
All three elements of OCE are important 227
The impact of improving both craft utilization and performance 227
Summary of Our Previous Examples 229
Where can we apply OCE gained value 229
Indiscriminate cutting of maintenance is blood letting 229
Think profit centered 230
Maintenance is forever 230
Chapter 15. The ACE Team Benchmarking Process: A New
Benchmarking Tool 231
The ACE System Supports Continuous Reliability Improvement 235
The ACE System: A Team-Based Approach 235
Gaining Acceptance for Maintenance Performance Standards 236
The Basic Approach: A Simple 10-Step Procedure That Works 236
Important note 238
ACE system work groupings and time ranges 240
Spreadsheets provide means for work content comparison 240
The 10-Step Procedure for Using the ACE System 241
Chapter 16. Profit-and Customer-Centered Best Practices 247
Continuous Reliability Improvement (CRI) 247
Critical Asset Facilitation 250
Preventive Maintenance (PM) 252
Predictive Maintenance (PdM) 253
Maintenance Storeroom Operations 257
Storeroom inventory management 259
The five levels to world s best practice inventory management 260
MRO Materials Management and Purchasing 261
The Storeroom:The Foundation for Effective Maintenance 262
The high cost of low-bid buying 263
The life-cycle information loop 264
Teamwork works for achieving purchasing excellence 264
Develop win-win alliances with vendors 266
Planning and Scheduling 267
Reliability-Centered Maintenance (RCM) 269
The evolution of RCM 269
Overview of the RCM process 269
Operator-based Maintenance (OBM) 271
x Contents
Chapter 17. Maintenance Quality and Customer Service 275
It Takes More Than Software to Reach Best Practice 278
Chapter 18. Case Study—Critical Asset Facilitation: A Lesson
Learned at Boeing Commercial Airplane Group 281
A Strong Internal Technical Team Is Required 282
Understand benefits, purpose, and results 283
Asset facilitation process results 283
Review of the PM analysis process 284
OBM became an additional best practice option 285
Ten Important Lessons Learned 286
Asset Facilitation Supports QS9002 Compliance and Technical Imaging 287
Summary 287
Chapter 19. PRIDE in Ownership with Operator-Based
Maintenance 289
Profit-Centered Fuel Management 294
Higher cost—not lower fuel cost 294
Fuel management enhances preventive maintenance 295
Chapter 20. Case Study: Developing an Effective Preventive
Maintenance Strategy 297
Introduction 297
What Are the Choices for a Maintenance Strategy? 297
The Recommended Approach 298
Phase I—Top leader awareness of PM benefits 298
Phase II—Top leader commitment to PM 300
Phase III—Pilot PM program design and implementation 301
Phase IV—Evaluate pilot program 303
Phase V—Expand and operate the total PM program 305
Phase VI—Continuous reliability improvement and evaluation 306
Summary: 22 Key Points to Ensure a Successful PM Program 307
Chapter 21. Today s Predictive Maintenance Technology: Key to
Continuous Reliability Improvement 309
Difference between PM and PdM 310
PM—An interval-based system 310
PdM—A condition-based system 311
Principal Advantages of PdM 312
Determining When to Use PdM 312
Putting Predictive Technology Tools to Work for You 313
Vibration analysis 313
Shock pulse 315
Spectrometric oil analysis 316
Standard oil analysis 317
Ferrographic oil analysis 317
Infrared thermography 319
Contents xi
Ultrasonic detection 321
Tailor the PdM technology to your operation 322
Implementing a PdM Program 323
The Basic Steps for Implementing a Vibration Analysis Program 324
Step 1: Select equipment to be monitored 324
Step 2: Establish vibration limits 325
Step 3: Select check points 327
Step 4: Check overall vibration level and correct existing deficiencies
in start-up machines 327
Step 5: Determine optimum check intervals 328
Step 6: Collect baseline information 328
Step 7: Design a data-collection process 329
Step 8: Implement training for vibration analysis 329
Conclusion 332
Chapter 22. Auto Identification Strategies to Support
Maintenance Storeroom Excellence 333
Assume RFID Technology Is Cost Effective 333
What Is RFID? 334
How does RFID work? 334
Glossary of Bar Code and RFID Terms 335
Bar code 335
Radio frequency identification (RFID) 335
Frequency 336
Interrogation and Reader Definitions and Functional Capabilities 337
Sensor 337
Implementation Strategies 338
Strategic Planning 338
Detailing the System 340
The Big Sell Not the Big Chill 340
Chapter 23. Case Study: Planning for Maintenance Excellence
in Action at Lucent Technologies 343
Taking the Next Important Steps 343
Maintenance Planners: A Critical Technical Resource 344
Metrics to Measure Results and Total Operations Success 345
Results translate to your bottom line 346
Determining Your Overall Baseline 346
Conclusion: Maintenance Operations can Plan for Maintenance Excellence 347
Part 5 Validating Best Practice Results with
the Maintenance Excellence Index
Chapter 24. Determine and Quantify Benefits and Gained Value 351
General Benefits 352
Sources of Benefits and Gained Value from Investments in Maintenance 353
Craft labor productivity 353
MRO materials costs 354
xii Contents
Major project cost savings 355
Asset availability and throughput cost savings 355
Other Important Areas Providing Benefits 362
The quality improvement impact of maintenance excellence 362
Paperwork/Clerical Savings 363
Maintenance paperwork/clerical cost justification 363
Clerical/paperwork savings for purchasing 363
Clerical/paperwork savings for engineering 364
Summary 364
Chapter 25. Developing Your Maintenance Excellence Index to
Validate Results 367
Developing Key Performance Indicators 367
Develop Method to Measure and Validate Results 372
Initiate a maintenance excellence index 373
Your MEI Validates Your Results 381
Get started now 381
Chapter 26. Nontraditional Return on Investment for Improving
Your Maintenance Return on Investment 385
Traditional ROI 386
General benefits 387
Specific benefits 387
Impact on sales 388
Leadership and the Return on Inspirational Leadership (ROIL) 389
Beyond the Bottom Line 390
Return on inspiration (ROInspire) 391
Return on insight, intent, and initiative (ROIII) 392
Return on integrity (ROInteg) 393
Return on information (ROInfo) 394
Return on interaction and integration (ROM) 396
Return on imagination, ingenuity, and improvement (ROImlnglmp) 396
Return on individuals and intelligence (ROIndlntel) 398
Return on innovation and ideas (ROInolde) 399
Return on implementation and impact (ROImplmpac) 400
Conclusion 401
Part 6 The Journey toward Maintenance Excellence
Chapter 27. Developing and Implementing a Profit-Centered
Action Plan 405
The Real Work Is Implementation 407
What is Business Process Blueprinting? 408
Return on investment for effort (ROIEff) 409
Maximize your return on investment 409
How to Do Business Process Blueprinting? 410
Ongoing Support 411
Monitor compliance 411
Contents xiii
Chapter 28. Achieving PRIDE in Maintenance 413
PRIDE in Excellence 413
PRIDE in Maintenance 415
A positive and proven approach 418
Gain support of craft workforce 420
Systems Performance Team Chartered 422
Summary 423
Chapter 29. The Journey toward Maintenance Excellence: 425
Where Will You Go Now?
Nothing Happens Until Someone Sells Something 430
Appendix A. The Scoreboard for Maintenance Excellence 433
Appendix B. The CMMS Benchmarking System 461
Appendix C. CMMS Functionality Rating Checklist 467
Appendix D. Case Study: What Do Your Crafts Think about CMMS? 479
Appendix E. Maintenance Excellence Glossary 483
Appendix F. Maintenance Excellence Strategy Team Charter Example 513
Appendix G. ACE Team Benchmarking Team Charter Example 517
Appendix H. ACE Team Forms 521
Appendix I. OEE and Maintenance 5S Forms 529
Appendix J. Customer Service Pocket Pal Example 533
Appendix K. A 1999 Vision of Maintenance at the Millennium:
Revisited in 2006 537
Appendix L. Comparison of Scoreboards 545
Index 549
|
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| discipline | Wirtschaftswissenschaften |
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| id | DE-604.BV035447685 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T21:35:29Z |
| institution | BVB |
| isbn | 0071463399 9780071463393 |
| language | English |
| lccn | 2006044861 |
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| spelling | Peters, Ralph W. Verfasser aut Maintenance benchmarking and best practices a profit- and customer-centered approach Ralph W. "Pete" Peters New York [u.a.] McGraw-Hill 2006 XXX, 566 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier McGraw-Hill maintenance Usines - Entretien - Gestion Étalonnage concurrentiel Plant maintenance Management Benchmarking (Management) Management (DE-588)4037278-9 gnd rswk-swf Instandhaltung (DE-588)4027145-6 gnd rswk-swf Instandhaltung (DE-588)4027145-6 s Management (DE-588)4037278-9 s DE-604 http://www.loc.gov/catdir/enhancements/fy0634/2006044861-b.html Contributor biographical information http://www.loc.gov/catdir/enhancements/fy0634/2006044861-d.html Publisher description http://www.loc.gov/catdir/enhancements/fy0634/2006044861-t.html Table of contents HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017367806&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Peters, Ralph W. Maintenance benchmarking and best practices a profit- and customer-centered approach Usines - Entretien - Gestion Étalonnage concurrentiel Plant maintenance Management Benchmarking (Management) Management (DE-588)4037278-9 gnd Instandhaltung (DE-588)4027145-6 gnd |
| subject_GND | (DE-588)4037278-9 (DE-588)4027145-6 |
| title | Maintenance benchmarking and best practices a profit- and customer-centered approach |
| title_auth | Maintenance benchmarking and best practices a profit- and customer-centered approach |
| title_exact_search | Maintenance benchmarking and best practices a profit- and customer-centered approach |
| title_full | Maintenance benchmarking and best practices a profit- and customer-centered approach Ralph W. "Pete" Peters |
| title_fullStr | Maintenance benchmarking and best practices a profit- and customer-centered approach Ralph W. "Pete" Peters |
| title_full_unstemmed | Maintenance benchmarking and best practices a profit- and customer-centered approach Ralph W. "Pete" Peters |
| title_short | Maintenance benchmarking and best practices |
| title_sort | maintenance benchmarking and best practices a profit and customer centered approach |
| title_sub | a profit- and customer-centered approach |
| topic | Usines - Entretien - Gestion Étalonnage concurrentiel Plant maintenance Management Benchmarking (Management) Management (DE-588)4037278-9 gnd Instandhaltung (DE-588)4027145-6 gnd |
| topic_facet | Usines - Entretien - Gestion Étalonnage concurrentiel Plant maintenance Management Benchmarking (Management) Management Instandhaltung |
| url | http://www.loc.gov/catdir/enhancements/fy0634/2006044861-b.html http://www.loc.gov/catdir/enhancements/fy0634/2006044861-d.html http://www.loc.gov/catdir/enhancements/fy0634/2006044861-t.html http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017367806&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT petersralphw maintenancebenchmarkingandbestpracticesaprofitandcustomercenteredapproach |