Effective Maintenance Management: Risk and Reliability Strategies for Optimizing Performance

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Industrial Press Inc., 2004 - Technology & Engineering - 246 pages
1 Review
... this book has the depth and content to really help maintenance organizations change and improve reliability. This is a book with true content, without having to own numerous other books to provide information one might need. Great book...Ricky Smith, Executive Director, Maintenance Solutions.


Providing a clear explanation of the value and benefits of maintenance, this unique guide is written in a language and style that practicing engineers and managers can understand and apply easily. Effective Maintenance Management examines the role of maintenance in minimizing the risk of safety or environmental incidents, adverse publicity, and loss of profitability. In addition to discussing risk reduction tools, it explains their applicability to specific situations, thereby enabling you to select the tool that best fits your requirements. Intended to bridge the gap between designers/maintainers and reliability engineers, this guide is sure to help businesses utilize their assets more effectively, safely, and profitably.

 

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Contents

The production and distribution process
1
11 PROCESS EFFICIENCY
2
113 Cost measurement and pitfalls
3
12 WORK AND ITS VALUE
4
13 MANUFACTURING AND SERVICE INDUSTRIES
5
14 THE SYSTEMS APPROACH
6
15 IMPACT OF EFFICIENCY ON RESOURCES
7
152 Efficiency and nonrenewable resources
8
72 DESCRIPTIVE OR QUALITATIVE RISK
118
722 The influence of choice
119
723 Control of situation
120
724 Delayed effects on health
121
727 Subjectivity
122
74 THE QUANTITATIVE ASPECTS OF RISK
123
742 Exposure
124
75 CHAPTER SUMMARY
125

17 CHAPTER SUMMARY
9
Process functions
11
22 FUNCTIONAL BLOCK DIAGRAMS FBD
13
23 FAILURE MODES AND EFFECTS ANALYSIS FMEA
17
24 EFFECTIVE PLANNING
19
26 CHAPTER SUMMARY
20
Reliability engineering for the maintenance practitioner
23
32 PROBABILITY DENSITY FUNCTION
25
33 MORTALITY
26
34 HAZARD RATES AND FAILURE PATTERNS
27
35 THE TROUBLE WITH AVERAGES
30
36 THE SPECIAL CASE OF THE CONSTANT HAZARD RATE
32
37 AVAILABILITY
33
38 MEAN AVAILABILITY
34
39 THE WEIBULL DISTRIBUTION
41
310 DETERMINISTIC AND PROBABILISTIC DISTRIBUTIONS
43
311 AGEEXPLORATION
44
Failure its nature ans characteristics
57
412 Critical and degraded failures
58
415 Incipient failures
59
43 THE FEEDBACK CONTROL MODEL
61
45 CAPABILITY AND EXPECTATION
62
46 INCIPIENCY
64
47 LIMITS TO THE APPLICATION OF CONDITION MONITORING
69
49 SYSTEM LEVEL FAILURES
70
411 CHAPTER SUMMARY
73
Life cycle aspects of risks in process plants
77
51 DESIGN QUALITY
79
511 Marketing inputs
80
513 Maintainability
81
514 Reliability
84
52 RISKS DURING CONSTRUCTION
88
54 PLANNING OF MAINTENANCE WORK
89
552 Competence and motivation
90
57 MAINTENANCE COSTS
92
571 Failure rates and their impact
93
573 Maintenance cost drivers shutdowns turnarounds
95
574 Breakdowns and Trips
97
Process plant shutdowns
99
612 Loss of efficiency
100
613 Incorporation of plant changes
101
63 PLANNING
102
641 Traffic safety
103
644 Fire and evacuation drills
104
648 Rescue planning
105
649 Medical support
106
66 QUALITY
107
662 Competence
108
68 EXECUTION
109
682 Competence
110
685 Closingup equipment
111
69 SPECIALIZED EQUIPMENT OVERHAULS
112
612 CONTRACTORS
113
614 POSTSHUTDOWN REVIEW
114
Facets of risk
117
The escalation of events
127
812 The Piper Alpha Explosion
128
813 Kings Cross underground station fire
133
815 Bhopal
134
82 HINDSIGHT IS 2020 VISION
135
83 FORESIGHT CAN WE IMPROVE IT?
137
85 DAMAGE LIMITATION MODEL
142
86 FAILURE OF BARRIERS
143
88 EVALUATING TEST FREQUENCIES
144
89 INCIPIENCY PERIOD
146
Maintenance
149
912 Applicable maintenance tasks
152
913 How much preventive maintenance should we do?
153
9J THE CONTINUOUS IMPROVEMENT CYCLE
156
932 Scheduling
158
933 Execution
159
934 Analysis
161
94 SYSTEM EFFECTIVENESS AND MAINTENANCE
163
942 Dutystandby operation
168
943 Endtoend testing of control loops
170
95 CHAPTER SUMMARY
172
Risk reduction
177
102 RELIABILITY BLOCK DIAGRAMS AND MATHEMATICAL MODELING
179
103 HAZARD AND OPERABILITY STUDIES
182
105 ROOT CAUSE ANALYSIS
183
106 TOTAL PRODUCTIVE MAINTENANCE
187
107 RELIABILITY CENTERED MAINTENANCE
188
1071 Functional block diagrams
189
1073 Failure characteristic analysis FCA
190
1074 Applicable and effective maintenance tasks
193
1075 Costeffective maintenance tasks
197
1077 Preventive maintenance routines
198
1078 Structural and Zonal RCM Analysis
200
1091 David and Goliath scenarios
201
1092 Influence of perceptions
202
Information for decision making
205
112 THE COLLECTION OF QUANTITATIVE DATA
206
113 THE COLLECTION OF MAINTENANCE DATA
207
1132 Reducing the consequence of failures
208
1133 Cost data
209
114 THE COLLECTION OF QUALITATIVE DATA
211
115 ERRORS IN DATA COLLECTION
212
116 FIXED FORMAT DATA COLLECTION
213
117 OBTAINING INFORMATION FROM DATA
215
118 DECISION SUPPORT
216
119 PROCEDURES
217
Improving System Effectiveness
225
122 INTEGRITY AND SYSTEM EFFECTIVENESS
227
1233 Minimization of severity of incidents
228
1243 The process of carrying out maintenance
229
126 BRIDGING THE CHASM BETWEEN THEORY AND PRACTICE
230
128 CHAPTER SUMMARY
231
Glossary
239
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