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K. Venkataraman

Maintenance Engineering and Management

Maintenance Engineering and Management

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New Delhi-1100012010

Rs. 225.00

MAINTENANCE ENGINEERING AND MANAGEMENTK. Venkataraman

© 2007 by PHI Learning Private Limited, New Delhi. All rights reserved. No part of this book may bereproduced in any form, by mimeograph or any other means, without permission in writing from thepublisher.

ISBN-978-81-203-3130-3

The export rights of this book are vested solely with the publisher.

Fourth Printing ... ... ... ... October, 2010

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,New Delhi-110001 and Printed by Mudrak, 30-A, Patparganj, Delhi-110091.

Contents

Preface xi

1. Introduction to Maintenance Systems 1

1.1 Introduction 11.2 Definitions of Repair and Maintenance 11.3 Maintenance as Business Proposition 2

1.3.1 The Business Unit Concept 21.3.2 Automation 21.3.3 Maintenance Cost Reduction 2

1.4 History of Maintenance Business 31.5 Maintenance Philosophy 51.6 Different Maintenance Systems 5

1.6.1 Planned Maintenance 61.6.2 Preventive Maintenance 71.6.3 Predictive Maintenance 101.6.4 Proactive Maintenance 10

1.7 Maintenance Policies and Procedures Manual 111.8 Man Management Issues in Maintenance Function 12

1.8.1 Concept of Supervision 12Summary 15Review Questions 15Annexure 1 Benefits of Planned Maintenance—Departmentwise 16Annexure 2 Typical Failure Report and Action Taken 17

2. Maintainability 18

2.1 Introduction 182.2 Measure of Maintainability 19

2.2.1 Failure Rate Curves 202.2.2 Typical Bathtub Type of Failure Pattern2.2.3 Inherent and Operational Availability 212.2.4 Testability and Supportability 22

2.3 Methods of Evaluation of Maintainability 242.3.1 Procedure in Sampling and Testing 242.3.2 Test Plan for Determination of MTTR

(Mean Time to Repair or Maintainability) 252.3.3 Computerized Evaluation of MTTRs and Other Related Parameters 25

2.4 Design for Maintainability—An Overview 272.4.1 Some Guidelines for a “Good Design for Maintenance” 28

vi Contents2.4.2 Benefits of Deploying “Design for Maintainability” 292.4.3 Capabilities of a Proven Design System Incorporating “Design for Maintenance” 29

2.5 Designs for Reliability 31Summary 32Review Questions 32

3. Condition-Based Maintenance (CBM) 33

3.1 Introduction 333.2 Effectiveness Improvement through Condition Monitoring 333.3 Vibration Analysis 343.4 Ultrasonic Evaluation 363.5 Motor Condition Monitor 363.6 Thermography 373.7 Oil and Lubricant Analysis in CBM 38

3.7.1 Methods of Analysis of Oil and Lubricants 403.7.2 Degradation of Grease 433.7.3 Case Study of Engine Oils, Transmission Oil and Drive Train Oils 44

3.8 Gas-Leakage Detection 463.9 Alignment of Shafts 463.10 Typical Case Study 483.11 Non-destructive Testing (NDT) Techniques 48

3.11.1 Types of Non-destructive Testing 483.11.2 Comparative Analysis of NDT Techniques 49

3.12 Retirement for Cause 49Summary 51Review Questions 51Annexure 1 Equipment for Carrying Out Condition-Based Maintenance 52Annexure 2 Thermography 53

4. Reliability-Centred Maintenance (RCM) 60

4.1 Introduction 604.2 Practical Steps Towards Achieving Reliability-Centred Maintenance 614.3 Reliability Block Diagrams 644.4 Reliability While Being Active and Standby 65

4.4.1 Other General Features of Redundant Systems 664.5 Reliability-Centred Maintenance 66

4.5.1 Basic Guidelines of Reliability-Centred Maintenance 684.5.2 Case Study of Implementing RCM Techniques in Railways Other 69

4.6 Analytical Tools 704.6.1 Failure Modes Effects and Criticality Analysis (FMECA)4.6.2 Root Cause Failure Analysis (RCFA) 714.6.3 Logic Tree in Maintenance Management or in Root Cause Analysis 714.6.4 Criticality Analysis/Criticality Matrix 73

4.7 Difference between RCM and RCA (Root Cause Analysis) 76

vii Contents4.8 Event Tree Analysis 774.9 Prediction Model for Reliability 774.10 Use of Software in Carrying Out Reliability-Centred Maintenance 78Summary 80Review Questions 80

5. Asset and Spare Parts Management 82

5.1 Introduction 825.2 Asset Management Function in 21st Century Organizations 82

5.2.1 Financial Asset Management 835.2.2 Human Asset Management 835.2.3 Physical Asset Management 835.2.4 Comparative Analysis of Asset Functions 84

5.3 Conventional Systems of Ordering Spare Parts and Materials 875.4 Economic Order Quantity 875.5 Two-Bin System of Material Procurement5.6 Materials Management Manual 925.7 Proven, and New Approaches in Effective Asset/Spare Parts

Management Programme 925.8 Mobile Computing and Use of Bar Code Technology for

Spare Parts Tracking and Monitoring 96Summary 98Review Questions 99Annexure Key Definitions 100

6. Safety Engineering and Fault Tree Analysis 101

6.1 Introduction 1016.2 Hazard Analysis 1026.3 Codes and Standards in Occupational Safety and Health (OSH) 105

6.3.1 Benefits of Occupational Safety 1056.4 Case Study of an Automobile Repair Shop Hazard Prevention 107

6.4.1 Hazards due to Faulty Work Habits or Conditions 1076.4.2 Hazards due to Equipment Defects 1086.4.3 Types of Fire Extinguishers (Figures 6.4 and 6.5) and Their Applications 1096.4.4 Salient Points in the Safe Maintenance Work of An Automobile 110

6.5 General Rules in Fire Hazard and Safety 1116.5.1 Electrical Hazards 1116.5.2 Hazards Caused due to Ergonomics 1136.5.3 Smoking 1146.5.4 Chemical Hazard and Prevention 1146.5.5 Responsibilities of Supervisors in Safety 1146.5.6 Programme Evaluation Procedures in Safety 114

6.6 Fault Tree Analysis 1156.6.1 Purpose of Fault Tree Analysis 115

viii Contents6.6.2 Description of Fault Tree Analysis 1166.6.3 Nomenclature of Various Symbols in Fault Tree 117

6.7 Sneak Circuit Analysis 1186.8 Failure Mechanisms 118Summary 119Review Questions 119Annexure Important Definitions on Safety 120

7. Total Productive Maintenance 122

7.1 Introduction 1227.2 TPM Methodology of Working 1227.3 The “Big Six” Wastes Which are Being Eliminated by TPM 1237.4 Total Productive Maintenance 1237.5 Origin of the Concept of TPM 1237.6 Implementation of TPM 1247.7 Major Road Map of TPM 1257.8 World-Class Maintenance Organization 1257.9 Lean Maintenance 1277.10 Training and Mentoring for Implementation of Proactive Maintenance/Total Productive

Maintenance/Lean Maintenance 1317.10.1 Mentoring 1327.10.2 Training by Example 1327.10.3 Metrics for Measurement of Culture Change 132

7.11 Business-Centred Maintenance 133Summary 133Review Questions 134

8. Maintenance Planning and Scheduling 135

8.1 Introduction 1358.2 Maintenance Planning 1368.3 Shutdown Planning and Execution 138

8.3.1 Salient Features of Shutdown Planning and Execution 1398.3.2 Monitoring of Shutdown Function 1418.3.3 Sequencing of Activities in a Machine Shutdown 142

8.4 Review of the Effectiveness of Proactive Shutdown 143Summary 144Review Questions 145

9. Computer Applications in Maintenance Management 146

9.1 Introduction 1469.2 Determining the Business Objectives and the Role of CMMS 1479.3 Data Acquisition 149

9.3.1 The Wireless Method 150

Maintenance Engineering AndManagement

Publisher : PHI Learning ISBN : 9788120331303Author : VENKATARAMAN,K.

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