Engineering Maintenance

Of the more than $300 billion spent on plant maintenance and operations, U.S. industry spends as much as 80 percent of this amount to correct chronic failures of machines, systems, and people. With machines and systems becoming increasingly complex, this problem can only worsen, and there is a clear and pressing need to establish comprehensive equipment management programs that incorporate the diverse considerations that are essential to effective maintenance.

Engineering Maintenance: A Modern Approach presents a cradle-to-grave strategy to preserve equipment function, avoid the consequences of failures, and ensure the productive capacity of equipment. Moving well beyond traditional approaches, this strategy incorporates quality and safety, human error, and software maintenance considerations along with costing, reliability, and maintainability. From specialized books and technical articles, the author has gathered and integrated the latest advances in engineering maintenance into practical, step-by-step plans designed to optimize maintenance activities, extend equipment life, and minimize failures.

The elimination of chronic failures through effective maintenance can reduce maintenance costs by 40 to 60 percent. Engineering Maintenance: A Modern Approach not only collects recent advances into a single volume, but also directs you on a path that can lead to a more successful, cost-effective maintenance program.

Table of Contents

INTRODUCTION

Need for Maintenance

Facts and Figures

Modern Maintenance Problem and Maintenance Strategy for the 21st Century

Engineering Maintenance Objectives and Maintenance in Equipment Life Cycle

Terms and Definitions

MAINTENANCE MATHEMATICS

Basic Laws of Boolean Algebra

Probability Definitions and Properties

Probability Distributions

Laplace Transforms

Initial and Final Value Theorems

Equation Roots

Linear Differential Equations

MAINTENANCE MANAGEMENT AND CONTROL

Maintenance Manual

Maintenance Facility Evaluation

Functions of Effective Maintenance Management

Maintenance Project Control Methods

Maintenance Management Control Indices

PREVENTIVE MAINTENANCE

Elements of Preventive Maintenance Program

Establishing Preventive Maintenance Program

PM Program Evaluation and Improvement

PM Measures

PM Models

CORRECTIVE MAINTENANCE

Corrective Maintenance Types

Corrective Maintenance Steps and Downtime Components

Corrective Maintenance Measures

Corrective Maintenance Models

RELIABILITY CENTERED MAINTENANCE

RCM Goals and Principles

RCM Process and Associated Questions

RCM Program Components

RCM Effectiveness Measurement Indicators

RCM Benefits and Reasons for Its Failures

INVENTORY CONTROL IN MAINTENANCE

Inventory Control Objectives and Basic Inventory Decisions

ABC Inventory Control Method

Inventory Control Models

Two-Bin Inventory Control and Safety Stock

Spares Determination Factors

Spares Calculation Methods

HUMAN ERROR IN MAINTENANCE

Facts and Figures Concerning Human Factors in Maintenance

Maintenance Error in System Life Cycle and Breakdown of Maintenance Person's Time

Top Human Failure Problems in Maintenance and Classifications of Maintenance Error

Frequency of Maintenance Error Types and Outcomes of Maintenance Incidents

Reasons for Maintenance Error

Guidelines for Reducing Human Error in Maintenance

Techniques for Predicting the Occurrence of Human Error in Maintenance

QUALITY AND SAFETY IN MAINTENANCE

Needs for Quality Maintenance Processes

Maintenance Work Quality

Use of Quality Control Charts in Maintenance Work Sampling

Post Maintenance Testing

Reasons for Safety Problems in Maintenance

Guidelines to Improve Safety in Maintenance Work

Safety Officer's Role in Maintenance Work

Protection of Maintenance Workers

MAINTENANCE COSTING

Reasons for Maintenance Costing

Maintenance Budget Preparation Methods and Steps

Maintenance Labor Cost Estimation

Material Cost Estimation

Equipment Life Cycle Maintenance Cost Estimation

Maintenance Cost Estimation Models

SOFTWARE MAINTENANCE

Software Maintenance Facts and Figures

Maintenance Effort Distribution and Request Types and Categories

Software Maintenance Activities

Software Maintenance Characteristics and Tools

Software Maintenance Cost Estimation Related Models

RELIABILITY

Reliability Versus Maintenance and Reliability in Support Phase

Bathtub Hazard Rate Concept

Reliability Measures and Formulas

Reliability Networks

Reliability Analysis Techniques

MAINTAINABILITY

Maintainability Importance and Objective

Maintainability in Systems Life Cycle

Maintainability Design Characteristics

Maintainability Functions and Measures

Common Maintainability Design Errors

Each chapter also includes Introduction, Problems, and References sections.