Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM)

240 Pages·2012·9.41 MB·English

by  Kern Peng

Equipment
Management in the
Post-Maintenance Era
A New Alternative to Total
Productive Maintenance (TPM)

Equipment
Management in the
Post-Maintenance Era
A New Alternative to Total
Productive Maintenance (TPM)
KERN PENG
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
© 2012 by Taylor & Francis Group, LLC
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Version Date: 20111122
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This book is dedicated to my wife, Patricia, who is the coach
of my pursuits, and to my two daughters, Ilena and Elena,
who are the cheerleaders along my journey.

Contents
List of Figures .....................................................................................xiii
List of Tables .........................................................................................xv
Preface .................................................................................................xvii
Acknowledgments ...............................................................................xxi
About the Author ..............................................................................xxiii
Section i introduction to
equipment Management
chapter 1 Introduction .......................................................................3
Background ..................................................................................3
Maintenance Management ........................................................6
Equipment Management ............................................................7
Key Equipment Terminology .....................................................8
Equipment States ....................................................................8
Equipment Time .....................................................................8
Equipment Actions ...............................................................11
Equipment Failure Patterns ................................................12
Equipment Performance Measurements ...........................14
chapter 2 History of Equipment Management ...............................17
Introduction ...............................................................................17

Phase 1: Breakdown Management ..........................................17
Phase 2: Preventive Maintenance ............................................18
Phase 3: Productive Maintenance ..........................................20
Phase 4: Total Productive Maintenance .................................22
Phase 5: TPM with Predictive Maintenance..........................25
Summary of the Pre-maintenance and Maintenance
Phases ..........................................................................................26
vii
viii  •  Contents
chapter 3 Introduction to the Post-Maintenance Era ....................29
The New Business Environment .............................................29
Operational Changes...........................................................30
Equipment Characteristics ..................................................31
New Enabling Technologies ................................................33
New Management Concepts ...............................................35
The Issues of Maintenance .......................................................36
Problems in Objectives ........................................................37
Structural Inefficiency..........................................................38
Unsuitable for Changing Environment .............................39
Introduction to Phase 6: Post-Maintenance Era ..................40
Section ii the Maintenance System
chapter 4 General Maintenance Concepts and Practices ..............45
Introduction ...............................................................................45
Preventive Maintenance ...........................................................45
Preventive Maintenance Schedule......................................47
Preventive Maintenance Task List ......................................50
Preventive Maintenance Staffing Requirements ..............52
Preventive Maintenance Equipment/Tool
Requirements ........................................................................53
Preventive Maintenance Materials/Parts Requirements ...54
Preventive Maintenance Information System .................54
Reliability-Centered Maintenance ..........................................55
Predictive Maintenance ............................................................58
Maintenance Prevention ..........................................................61
Total Productive Maintenance ................................................63
Terotechnology ..........................................................................65
chapter 5 Maintenance Management Logistics ..............................67
Introduction ...............................................................................67
Planning and Budgeting ...........................................................67
Strategic Planning in Maintenance ...................................68
Headcount Plan .....................................................................70
Budget Plan ............................................................................75
Tactical Planning in Maintenance .....................................82
Contents  •  ix
Training and People Development .........................................85
Customer Services and Management .....................................92
Vendor, Supplier, and Contract Management .......................95
Inventory Management .........................................................100
chapter 6 Maintenance Performance Indicators ..........................105
Introduction .............................................................................105
Equipment Performance Indicators ......................................106
Safety Indicators .................................................................106
Purpose ............................................................................106
Format and Variation ....................................................106
Presentation ....................................................................107
Availability Indicators ........................................................107
Purpose ............................................................................107
Format and Variation ....................................................108
Presentation ....................................................................109
Reliability Indicators ..........................................................110
Purpose ............................................................................110
Format and Variation ....................................................110
Presentation ....................................................................112
Maintainability Indicators ................................................113
Purpose ............................................................................113
Format and Variation ....................................................113
Presentation ....................................................................114
Utilization Indicators .........................................................115
Purpose ............................................................................115
Format and Variation ....................................................116
Presentation ....................................................................117

Process Performance Indicators ............................................117
Labor Productivity Indicators...........................................118
Purpose ............................................................................118
Format and Variation ....................................................118
Presentation ....................................................................119
Nonproductive Downtime Indicators .............................119
Purpose ............................................................................119
Format and Variation ...................................................120
Presentation ...................................................................120
x  •  Contents
Customer Satisfaction Indicators .....................................121
Purpose ............................................................................121
Format and Variation ....................................................121
Presentation ...................................................................122
Operational Misses and Error Rates ...............................122
Purpose ...........................................................................122
Format and Variation ...................................................122
Presentation ...................................................................123
Cost Performance Indicators ................................................124
Cost Rates ...........................................................................124
Purpose ...........................................................................124
Format and Variation ...................................................124
Presentation ....................................................................125
Cost Breakdown by Categories .........................................125
Purpose ............................................................................125
Format and Variation ...................................................126
Presentation ...................................................................126
chapter 7 Computerized Maintenance Management Systems .....127
Introduction .............................................................................127
CMMS Objectives ..................................................................128
CMMS Functions ....................................................................132
Equipment Module .............................................................132
Work Order Module ...........................................................132
Preventive Maintenance Module ......................................133
Safety Module .....................................................................134
Labor Module .....................................................................134
Inventory Module ..............................................................134

Financial Module ................................................................135
Calendar Module ................................................................135
CMMS Features .......................................................................136
Accessibility and Security..................................................136
Communication and Notification ....................................137
Data Entry and Presentation .............................................138
Integration ...........................................................................139
Flexibility and Customization ..........................................140
CMMS Implementation ..........................................................141