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Productivity and Reliability-Based Maintenance Management, Second Edition is intended to provide a strong yet practical foundation for understanding the concepts and practices of total productive maintenance (TPM) managementa proactive asset and resource management strategy that is based on enhancing equipment reliability and overall enterprise productivity. The book is intended to serve as a fundamental yet comprehensive educational and practical guide for departing from the wait-failure-emergency repair cycle that has plagued too many industries, instead advancing a proactive and productive maintenance strategy. It is not intended to be a how-to-fix-it manual, but rather emphasizes the concept of a world-class maintenance management philosophy to avoid the failure in the first place. Universities, junior and community colleges, and technical institutes as well as professional, corporate, and industrial training programs can benefit by incorporating these fundamental concepts in their technical and managerial curricula. The book can serve as a powerful educational tool for students as well as for maintenance professionals and managers.





In addition to updating the previous historical and statistical data and tables, the second edition expands on and adds to case studies based on current maintenance-related events. Several numerical examples and explanations are revised in order to enhance the clarity of the methodology. The second edition introduces the readers to the state-of-the-art concepts of the Internet of Things (IoT), smart sensors, and their application to maintenance and TPM.
About the Author xiii
Preface xv
Acknowledgments xvii
1 Introduction
1(24)
1.1 Introduction to Maintenance Management
2(2)
1.1.1 Definition of Maintenance
2(2)
1.2 Maintenance Objectives
4(2)
1.2.1 Primary Goals
6(1)
1.2.2 Secondary Goals
6(1)
1.3 Management and Structure of the Maintenance Function
6(1)
13.1 Planning
7(1)
1.3.2 Scheduling
7(1)
1.4 Total Productive Maintenance (TPM)
8(2)
1.4.1 Definition
8(1)
1.4.2 Operator Responsibility
9(1)
1.4.3 Obstacles to Achieving Full Equipment Effectiveness
9(1)
1.5 Types of Maintenance Activities
10(1)
1.5.1 Reactive or Corrective Maintenance
10(1)
15.2 Preventive Maintenance (PM)
10(1)
1.5.3 Predictive Maintenance (PDM)
11(1)
1.6 Maintenance Department Organization
11(3)
1.6.1 Centralized Maintenance Department
12(1)
1.6.2 Decentralized Maintenance Organizations
12(1)
1.6.3 Combined System
13(1)
1.7 Maintenance in Service Industries
14(8)
Case in Point: The Crash of Flight 261
17(4)
Case in Point: The Collapse of the Condominium in Florida
21(1)
1.8 Changing Maintenance Strategies
22(3)
2 Statistical Applications
25(40)
2.1 Reliability
26(1)
2.2 System Reliability
26(2)
2.2.1 Series Systems
27(1)
2.3 Failure Rate
28(1)
2.3.1 Determining the Failure Rate
28(1)
2.4 Mean Time Between Failures, Availability, and Mean Downtime
29(1)
2.4.1 MTBF Defined
29(1)
2.4.2 Calculating MTBF
30(1)
2.5 Improving System Reliability
30(2)
2.5.1 Parallel Systems
30(1)
2.5.2 Combinations of Series and Parallel Systems
31(1)
2.5.3 Comparative Analysis of Series and Parallel Systems
32(1)
2.6 Equipment Life Cycle Failure Rate
32(3)
2.6.1 Infant Mortality
32(3)
2.6.2 Chance Failure
35(1)
2.6.3 Wear-Out Phase
35(1)
2.7 Exponential Probability Distribution
35(4)
2.7.1 Weibull Distribution
36(3)
2.8 Graphical Analysis
39(5)
2.8.1 Obtaining Reliability Data from a Graph
42(1)
2.8.2 Determining the Desired PM Interval from a Graph
43(1)
2.9 Mathematical Analysis
44(11)
2.9.1 Failure Rate Equation
44(1)
2.9.2 Reliability at Time (t)Equation
44(2)
2.9.3 Economics of Acceptable Risk Levels
46(2)
Case in Point: A Reliability Study for a Diesel Engine
48(7)
2.10 Queuing Theory and Applications
55(10)
2.10.1 Queuing Models
55(4)
2.10.2 Basic Queuing Model Calculations
59(6)
3 Preventive Maintenance
65(20)
3.1 Preventive Maintenance
68(2)
3.1.1 Routine Preventive Maintenance
68(1)
3.1.2 Major Preventive Maintenance
69(1)
3.2 Equipment History
70(1)
3.2.1 Establishing and Updating History
70(1)
3.2.2 Determining Reliability, MTBF, and Availability
70(1)
3.3 Establishing a System of Criticality
71(2)
3.3.1 Three Degrees of Equipment Criticality
71(2)
3.4 Planning for Preventive Maintenance
73(2)
3.5 Design for Maintainability
75(1)
3.6 Cost of Preventive Maintenance
76(9)
Case in Point: The Plight of ComEd
81(4)
4 Predictive Maintenance
85(50)
4.1 Introduction
86(3)
4.1.1 Definition of Predictive Maintenance
86(1)
4.1.2 PDM's Reliance on Science and Technology
87(1)
4.1.3 Decision Factors Regarding PDM
87(1)
4.1.4 PDM's Quantitative Nature
88(1)
4.1.5 Approaches to Data Collection
88(1)
4.1.6 Data Analysis
88(1)
4.2 Predictive Maintenance Techniques
89(38)
4.2.1 Vibration Analysis
89(14)
Case in Point: Vibration Monitoring Averts Plant Failure
103(3)
4.2.2 Chemical Analysis
106(3)
4.2.3 Tribology
109(3)
4.2.4 Thermography
112(11)
4.2.5 Ultrasound Techniques
123(4)
4.3 TPM and Advanced Technologies
127(8)
4.3.1 Data and Machine Learning
127(1)
4.3.2 TPM in the Era of Industry 4.0
128(7)
5 Nondestructive Testing and Evaluation
135(16)
5.1 Introduction
136(1)
5.2 Eddy Current Testing
136(4)
Case in Point: The Inspection of Pressurized Water Reactors
139(1)
5.3 Radiography
140(5)
5.3.1 Radioscopy
143(1)
5.3.2 Neutron Radiography
144(1)
5.3.3 Tomography
144(1)
5.3.4 Magnetic Resonance Imaging
144(1)
5.3.5 Quantitative Radiography
144(1)
5.4 Liquid Penetrant Testing
145(1)
5.5 Magnetic Particle Testing
146(2)
5.5.1 Magnetic Particle Classification
148(1)
5.6 Holography
148(3)
6 Implementing TPM
151(22)
6.1 Total Productive Maintenance
152(1)
6.1.1 Successful Implementation of TPM
152(1)
6.2 A Change in the Corporate Culture
153(1)
6.2.1 Deming's Legacy
153(1)
6.3 Unions and TPM
154(1)
6.4 The TPM Journey
155(5)
6.4.1 Introducing and Promoting TPM
155(1)
6.4.2 Communicating the Goals and Objectives of TPM
155(1)
6.4.3 Assessing Current Conditions
156(1)
6.4.4 Assessing Current Maintenance Effectiveness
156(4)
6.5 Overall Equipment Effectiveness
160(2)
6.5.1 Availability
160(1)
6.5.2 Efficiency
161(1)
6.53 Quality
162(4)
6.6 TPM Activities and Processes
166(7)
6.6.1 Cleaning
166(1)
6.6.2 Developing Lubrication Standards
167(1)
6.6.3 Inspection
167(1)
6.6.4 Workstation Organization
168(1)
6.6.5 Continuous Process Improvement
168(5)
7 TPM Implementation and Process Improvement Tools
173(48)
7.1 Introduction
174(1)
7.2 Benchmarking
174(1)
7.2.1 A Blueprint for Benchmarking
175(1)
7.3 The Five Pillars of TPM
175(1)
7.3.1 TPM Principles
176(1)
7.4 The Eight Pillars of Maintenance
176(2)
7.5 Failure Mode and Effect Analysis
178(15)
7.5.1 FMEA Categories
180(1)
7.5.2 Performing a Service FMEA
181(8)
Case in Point: A Shocking FMEA
189(4)
7.6 Root Cause Analysis
193(12)
7.6.1 The Process of Root Cause Analysis
196(2)
7.6.2 Techniques for Root Cause Analysis
198(5)
7.6.3 Ishikawa Diagram
203(2)
7.7 Fault Tree Analysis
205(1)
7.8 Implementing a Solution
206(15)
7.8.1 Alternative Solutions
206(1)
7.8.2 Evaluating Alternative Solutions
207(1)
Case in Point: A Chain Is Only as Strong as Its Weakest Link
208(13)
8 Facility Maintenance Projects Planning and Control
221(48)
8.1 Facility Maintenance Projects
222(2)
8.1.1 Definition of a Maintenance Project
222(1)
8.1.2 Successful Project Management
223(1)
8.2 The Role of the Project Manager
224(4)
8.2.1 The Project Manager's Responsibilities
224(4)
8.3 Maintenance Operations Analysis
228(11)
8.3.1 Maintenance Operations Procedures
228(1)
8.3.2 Regular Maintenance Tasks Identified
229(2)
8.3.3 Implementing Specific Maintenance Activities
231(1)
8.3.4 Scheduling Work Items
231(6)
8.3.5 Time Estimates
237(1)
8.3.6 High-Level Estimates
238(1)
8.4 Project Management Tools and Techniques
239(13)
8.4.1 Basics of the CPM and PERT Networks
241(7)
8.4.2 PERT Network Probability Analysis
248(4)
8.43 CPM/Crash Analysis
252(6)
8.4.4 A Realistic (Complex) PERT Project Example
255(3)
8.5 Computer Program Solutions
258(11)
8.5.1 Activity-on-Node Network Diagram Convention
258(1)
8.5.2 More Computer Printout Examples
259(4)
8.5.3 Manual Forward/Backward Pass Procedures on Activity-on-Node Diagrams
263(6)
9 Computerized Maintenance Management Systems
269(14)
9.1 Introduction
270(1)
9.2 Basic Functions
271(12)
9.2.1 Labor Tracking
271(1)
9.2.2 Vendor and Manufacturer Information
272(1)
9.2.3 Inventory Management
272(1)
9.2.4 Equipment Records
272(2)
9.2.5 Scheduling
274(1)
9.2.6 Predictive Maintenance
274(3)
9.2.7 Work Orders
277(1)
9.2.8 Purchase Orders
278(1)
9.2.9 Security
278(1)
9.2.10 Reports
278(1)
Case in Point: CMMS and ISO/QS Certification
279(4)
Solutions and Answers to Selected Questions 283(18)
Index 301
Dr. Matthew P. Stephens is a professor in the School of Engineering Technology at Purdue University, where he conducts his research and teaches courses in total productive maintenance (TPM) management, facilities planning, statistical quality control, and design of experiments (DOE). Stephens holds undergraduate and graduate degrees from Southern Illinois University and the University of Arkansas, with specialization in operations management and statistics. Prior to joining academe, Stephens spent nine years with several manufacturing and business enterprises, including flatbed trailer and washer and dryer manufacturers. He also has been extensively involved as a consultant with a number of major manufacturing companies. Stephens has numerous publications to his credit in the areas of productivity, quality improvements, and lean production systems. He is the author of Manufacturing Facilities Design and Material Handling, Sixth Edition (Purdue University Press, 2019). Stephens has served various professional organizations including the Association of Technology, Management, and Applied Engineering (ATMAE), and the American Society for Quality, where he attained his training in CQE and Six Sigma.
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