Handbook of Maintenance Management and Engineering (eBook)

Dr Mohamed Ben-Daya has been a professor in the Department of Systems Engineering at King Fahd University of Petroleum and Minerals in Dhahran, Saudi Arabia, since 1999. He gained his PhD in Operations Research in 1988 from Georgia Institute of Technology, USA, where he also gained his MSc in 1984. Dr Ben-Daya’s research interests are: mathematical programming; production and inventory control; scheduling; and maintenance engineering and quality control. Dr Salih O. Duffuaa has been a professor in the Department of Systems Engineering at King Fahd University of Petroleum and Minerals in Dhahran, Saudi Arabia, since 1994. His research interests include: mathematical modelling; network flow; mathematical programming; quality assurance and control; maintenance engineering; and management optimization of quality and maintenance systems. Dr Duffuaa gained his PhD in Operations Research in 1982 from the University of Texas at Austin, USA. Dr Abdul Raouf has been a professor at the Institute of Management and Technology, University of Management and Leadership in Lahore, Pakistan, since 2000. He gained his PhD from the University of Windsor. Dr Jezdimir Knezvic established the self-financing centre for Management of Industrial Reliability, Cost and Effectiveness (MIRCE) at Exeter University in 1991, where he is still a professor. He has contributed to over 300 publications worldwide including books, papers and reports. Dr Knezvic gained his Bachelors degree, Masters degree and PhD from the University of Belgrade. Dr Daoud Ait-Kadi has been a professor in the Department of Mechanical Engineering at the Université Laval, Sainte-Foy, Quebec, since 1990. He gained his PhD from the Université de Montréal in 1985. Dr Ait-Kadi’s research interests include: design and control of production systems; optimization of the maintenance and reliability systems subject to random failures; optimization of a system’s life cycle; development of advanced technologies for the design and control of supply chains in a probabilistic context; optimization of validation texts for the reliability of innovative systems; and reliability.

Editors 3
Preface 5
Acknowledgements 8
Contents 9
List of Contributors 22
Part I Maintenance Organization 25
1 Maintenance Organization 26
1.1 Introduction 26
1.2 Maintenance Organization Objectives and Responsibility 28
1.3 Determinants of a Maintenance Organization 29
1.4 Design of the Maintenance Organization 31
1.5 Basic Types of Organizational Models 32
1.6 Material and Spare Parts Management 33
1.7 Establishment of Authority and Reporting 36
1.8 Quality of Leadership and Supervision 36
1.9 Incentives 36
1.10 Education and Training 37
1.11 Management and Labor Relations 37
1.12 Summary 38
References 38
2 Maintenance Productivity and Performance Measurement 39
2.1 Introduction 39
2.2 Performance Measurement and Maintenance Productivity 41
2.3 Maintenance Performance 43
2.4 Measurement of Maintenance Productivity 45
2.5 MPI Standards and MPIs as in Use in Different Industries 53
2.6 Concluding Remarks 61
References 61
Part II Methods and Tools in Maintenance 64
3 Failure Statistics 65
3.1 Introduction 65
3.2 Introduction to Probability 65
E 66
3.3 Probability Distributions 69
F(x) .. P(X .. x) .. f (t) for - .. .. x .. ... 70
3.4 Reliability and Failure Rate Functions 71
3.5 Commonly Used Distributions 74
3.6 Failure Statistics 83
xi yi xi yi xi 89
References 93
4 Failure Mode and Effect Analysis 94
4.1 Introduction 94
4.2 FMEA Defined 95
4.3 FMEA Process 97
4.4 FMEA Applications 102
4.5 Related Tools 102
References 109
Part III Maintenance Control Systems 110
5 Maintenance Control 111
5.1 Introduction 111
5.2 The Maintenance Control Function 113
5.3 The Control Process 114
5.4 Functional Structure of Maintenance Control 115
5.5 Work Order System 117
To be completed by the maintenance craftsmen 122
5.6 Tools Necessary for Effective Maintenance Control System 125
5.7 Effective Programs for Improving Maintenance Control 128
5.8 Summary 130
References 130
6 Guidelines for Budgeting and Costing Planned Maintenance Services 132
6.1 Introduction 132
6.2 An Overview of Budgeting and Costing Systems 133
6.3 Proposed Budgetary System 135
6.4 Planned Maintenance Job Costing 140
6.5 Summary and Conclusions 148
References 149
7 Simulation Based Approaches for Maintenance Strategies Optimization 150
7.1 Introduction 150
7.2 Reliability Models Estimation 151
7.3 Maintenance Performance 155
L 157
C .. ..T 157
C 157
7.4 Simulation Based Maintenance Framework 158
7.5 A Case Study 165
7.6 Conclusion 169
References 169
Part IV Maintenance Planning and Scheduling 171
8 Maintenance Forecasting and Capacity Planning 172
8.1 Introduction 172
8.2 Forecasting Basics 173
8.3 Qualitative Forecasting Techniques 174
8.4 Quantitative Forecasting Techniques 176
8.5 Error Analysis 187
8.6 Forecasting Maintenance Workload 188
8.7 Maintenance Capacity Planning 190
8.8 Deterministic Approaches for Capacity Planning 191
8.9 Stochastic Techniques for Capacity Planning 197
8.10 Summary 203
References 204
9 Integrated Spare Parts Management 206
9.1 Introduction 206
9.2 Spare Parts Identification and Classification 207
9.3 Determination of the Required Quantity of Spare Parts 208
9.4 Inventory Control Policies 216
9.5 Joint Maintenance and Provisioning Strategies 219
9.6 Inventory and Maintenance Policies for Reconditioned Spare Parts 224
9.7 Collaborative Management of Spare Parts 228
9.8 Conclusion 233
References 233
10 Turnaround Maintenance 238
10.1 Introduction 238
10.2 Turnaround Initiation 240
10.3 Work Scope 241
10.4 Long Lead Time Resources 242
10.5 Contractors 243
10.6 TAM Planning 243
10.7 TAM Organization 244
10.8 Site Logistics 245
10.9 TAM Budget 245
10.10 Quality and Safety Plans 246
10.11 TAM Communication Procedures 247
10.12 TAM Execution 248
10.13 TAM Closing and Final Report 248
10.14 Conclusion 249
References 250
11 Maintenance Planning and Scheduling 251
11.1 Introduction 251
11.2 Strategic Planning in Maintenance 254
11.3 Medium Range Planning 258
11.4 Short Range Planning 261
11.5 Maintenance Scheduling 261
11.6 Scheduling Techniques 264
.. 266
B C 269
D 269
H 269
E 269
F 269
G 269
A 269
I 269
11.7 Scheduling Using Computers 274
11.8 Summary 274
References 275
12 Models for Production and Maintenance Planning in Stochastic Manufacturing Systems 277
12.1 Introduction 277
12.2 Problem Statement and Preliminary Results 278
12.3 Dynamic Programming Approach 288
12.4 Linear Programming Approach 294
12.5 Conclusion 309
References 310
Part V Maintenance Strategies 314
13 Inspection Strategies for Randomly Failing Systems 315
13.1 Introduction 315
13.2 Basic Inspection Model 317
x (i ..1,2,...) 318
13.3 Extensions of the Basic Model 320
13.4 Inspection Models for Multi-component Systems 330
13.5 Conditional Maintenance Models 333
13.6 Conclusion 343
References 344
14 System Health Monitoring and Prognostics – A Review of Current Paradigms and Practices1 348
14.1 Maintenance Strategies: Motivations for Health Monitoring 348
14.2 Health Monitoring Paradigms 351
14.3 Health Monitoring Tools and Techniques 354
14.4 Case Studies in System Monitoring and Control 358
14.5 Organizations and Standards 363
14.6 Summary and Research Directions 367
References 368
15 Applied Maintenance Models 374
15.1 Introduction 374
15.2 Missile Maintenance 376
t 379
15.3 Phased Array Radar Maintenance 384
1. 388
2. 388
3. 388
(< )
( ) 389
15.4 Self-diagnosis for FADEC 391
15.5 Co-generation System Maintenance 398
References 403
16 Reliability Centered Maintenance 407
16.1 Introduction 407
16.2 RCM Philosophy 410
Process 411
Feedback 412
16.3 Failure and its Nature 414
16.4 RCM Methodology 415
16.5 RCM Implementation 421
16.6 Conclusion 424
References 424
17 Total Productive Maintenance 426
17.1 Introduction to TPM 426
17.2 Evolution Towards TPM 429
17.3 Need of TPM 431
17.4 Basic Elements of TPM 433
17.5 Roadmap for TPM Implementation 438
17.6 An Ideal TPM Methodology 444
17.7 Barriers in TPM Implementation 462
17.8 Success Factors for Effective TPM Implementation 465
17.9 Summary 467
References 467
18 Warranty and Maintenance 469
18.1 Introduction 469
18.2 Maintenance Modelling 470
0 472
t .. 472
0 472
.. 472
18.3 Warranties 473
18.4 Link Between Warranty and Maintenance 475
18.5 Maintenance Logistics for Warranty Servicing 478
18.6 Outsourcing of Maintenance for Warranty Servicing 482
18.7 Conclusions and Topics for Future Research 484
References 484
19 Delay Time Modeling for Optimized Inspection Intervals of Production Plant 487
19.1 Introduction 487
19.2 The DT Concept and Modeling Characteristics 488
19.3 The DT Models for Complex Plant 491
– 491
t 492
19.4 Delay Time Model Parameters Estimation 495
19.5 A Case Example 501
19.6 Other Developments in DT Modeling and Future Research Directions 504
References 505
20 Integrated E-maintenance and Intelligent Maintenance Systems 507
20.1 Introduction 507
20.2 Condition-based Maintenance Technology and the State of Development 509
20.3 Integrated E-maintenance Solutions and Current Status 511
20.4 Technical Framework for E-maintenance 515
20.5 Watchdog Agent-based Intelligent Maintenance Systems 519
20.6 Technology Integration for Advanced E-maintenance 528
20.7 Some Industrial Applications 536
20.8 Challenges of E-maintenance Application Solutions 544
20.9 Conclusion 546
References 547
Part VI Maintainability and System Effectiveness 553
21 Maintainability and System Effectiveness 554
21.1 Introduction 554
21.2 The Concept of Maintainability 557
21.3 Maintainability Analysis 568
21.4 Empirical Data and Maintainability Measures 578
21.5 Maintainability Engineering Predictions 583
21.6 Maintainability Engineering Management 599
21.7 Concluding Remarks 614
References 617
Part VII Maintenance Safety, Environment and Human Error 618
22 Safety and Maintenance 619
22.1 Setting the Scene 619
22.2 Definitions 621
22.3 The Maintenance Link to Safety 623
22.4 Maintenance Policies and Concepts vs Safety 635
22.5 Maintenance Safety and Accident Prevention 642
22.6 Safety Measurement 649
References 652
23 Maintenance Quality and Environmental Performance Improvement: An Integrated Approach 655
23.1 Introduction 655
23.2 Maintenance Quality 656
23.3 Lean Manufacturing – Maintenance Quality Relationship 662
23.4 Integrated Approach 666
23.5 Conclusion 669
References 669
24 Industrial Asset Maintenance and Sustainability Performance: Economical, Environmental, and Societal Implications 671
24.1 Introduction 671
24.2 Industrial Activities and Sustainability Trends 672
24.3 Sustainability Performance in Perspective 674
24.4 Sustainability Performance Framework: From Business to Asset 677
24.5 Defining Maintenance Custodianship Within an Asset’s Sustainability Performance 682
24.6 Generic Maintenance Impact Management Process 689
24.7 Adapting an Effective Asset Maintenance Practice for Sustainability 692
24.8 Conclusion 695
References 695
25 Human Reliability and Error in Maintenance 700
25.1 Introduction 700
25.2 Terms and Definitions 700
25.3 Human Reliability and Error in Maintenance-Related Facts, Figures, and Examples 701
25.4 Occupational Stressors, Human Performance Effectiveness, and Human Performance Reliability Function 702
25.5 Human Error Occurrence Ways, Consequences, and Classifications, and Maintenance Error in System Life Cycle 705
25.6 Reasons for the Occurrence of Human Error in Maintenance and Top Human Problems in Maintenance 706
25.7 Mathematical Models for Performing Maintenance Error Analysis in Engineering Systems 707
25.8 Useful Guidelines to Reduce the Occurrence of Human Error in Maintenance 712
References 714
26 Human Error in Maintenance – A Design Perspective 716
26.1 Introduction 716
26.2 Human Error in Aircraft Maintenance 717
26.3 Significance of Maintenance Error 718
26.4 Design Impact 722
26.5 Analysis Required for Design Solutions 723
26.6 Design Strategies and Principles 731
26.7 Conclusion 739
References 740
Index 741