Handbook of Maintenance Management and Engineering

by Ben-Daya, Mohamed; Duffuaa, Salih O.; Raouf, Abdul; Knezevic, Jezdimir; Ait-Kadi, Daoud

• ISBN13: 9781848824713
• ISBN10: 1848824718
• Format: Hardcover
• Copyright: 2009-08-06
• Publisher: Springer Verlag

Summary

The Handbook of Maintenance Management and Engineering covers a wide range of topics in maintenance management and engineering. It includes extensive references to the theoretical foundations, recent research and future directions of this important subject. Using applications and examples which reflect the growing importance of maintenance, this book presents readers with an inter-disciplinary perspective on topical issues which affect any company engaged in discrete and process industry, no matter how large or small. Contributors to the book are maintenance experts with both academic and industrial backgrounds, who are able to offer a comprehensive analysis of the subject matter, including both quantitative treatment and discussion of management issues. The Handbook of Maintenance Management and Engineering features both fundamental and applied works from across the whole maintenance spectrum. It will provide professionals and researchers with the solutions and management skills needed to evaluate and to continuously improve maintenance systems.

Author Biography

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 Ph.D. in Operations Research in 1988 from Georgia Institute of Technology, USA where he also gained his M.Sc. in 1984. Dr. Ben-Daya's research interests are: mathematical programming, production and inventory control, scheduling, 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 Ph.D. 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 Ph.D. from the University of Windsor. Dr. Jezdimir Knezvic established a self-financing centre for Management of Industrial Reliability, Cost and Effectiveness (MIRCE) at Exeter University in 1991, at which he is a Professor. He has contributed to over 300 publications worldwide including books, papers and reports. Dr. Knezvic gained his Bachelors degree, Masters degree and Ph.D. from the University of Belgrade.Dr. Daoud Ait-Kadi has been a Professor in the Department of Mechanical Engineering at the Universit+¬ Laval, sainte-Foy, Quebec since 1990. He gained his Ph.D. from the Universit+¬ de Montr+¬al 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.

Table of Contents

List of Contributors	p. xxv
Maintenance Organization
Maintenance Organization	p. 3
Introduction	p. 3
Maintenance Organization Objectives and Responsibility	p. 5
Determinants of a Maintenance Organization	p. 6
Maintenance Capacity Planning	p. 6
Centralization vs Decentralization	p. 7
In-house vs Outsourcing	p. 7
Design of the Maintenance Organization	p. 8
Current Criteria for Organizational Change	p. 8
Criteria to Assess Organizational Effectiveness	p. 9
Basic Types of Organizational Models	p. 9
Material and Spare Parts Management	p. 10
Establishment of Authority and Reporting	p. 13
Quality of Leadership and Supervision	p. 13
Incentives	p. 13
Education and Training	p. 14
Management and Labor Relations	p. 14
Summary	p. 15
References	p. 15
Maintenance Productivity and Performance Measurement	p. 17
Introduction	p. 17
Performance Measurement and Maintenance Productivity	p. 19
Maintenance Performance	p. 21
Measurement of Maintenance Productivity	p. 23
Maintenance Performance Indicator (MPI)	p. 24
MPM Issues	p. 24
MPM System	p. 27
MPI Standards and MPIs as in Use in Different Industries	p. 31
Nuclear Industry	p. 32
Maintenance Indicators by EFNMS	p. 33
SMRP Metrics	p. 34
Oil and Gas Industry	p. 35
Railway Industry	p. 36
Process Industry	p. 36
Utility Industry	p. 37
Auto-industry Related MPIs for the CEO	p. 38
Concluding Remarks	p. 39
References	p. 39
Methods and Tools in Maintenance
Failure Statistics	p. 45
Introduction	p. 45
Introduction to Probability	p. 45
Sample Spaces and Events	p. 45
Definition of Probability	p. 46
Probability Rules	p. 46
Conditional Probabilities	p. 47
Random Variables	p. 48
Probability Distributions	p. 49
Reliability and Failure Rate Functions	p. 51
Introduction	p. 51
Reliability Function	p. 52
Failure Rate Function	p. 52
Mean Time Between Failure (MTBF)	p. 53
Commonly Used Distributions	p. 54
The Binomial Distribution	p. 54
The Poisson Distribution	p. 55
The Normal Distribution	p. 56
The Lognormal Distribution	p. 58
The Exponential Distribution	p. 60
The Weibull Distribution	p. 61
Failure Statistics	p. 63
Types of Data	p. 63
Parameter Estimation	p. 64
References	p. 73
Failure Mode and Effect Analysis	p. 75
Introduction	p. 75
FMEA Defined	p. 76
FMEA Process	p. 78
FMEA Applications	p. 83
Related Tools	p. 83
Root Cause Analysis	p. 83
Pareto Chart	p. 87
Cause and Effect Diagram	p. 87
References	p. 90
Maintenance Control Systems
Maintenance Control	p. 93
Introduction	p. 93
The Maintenance Control Function	p. 95
The Control Process	p. 96
Functional Structure of Maintenance Control	p. 97
Work Order System	p. 99
Basic Documentation for Work Order System	p. 99
Work Order System Flow	p. 105
Tools Necessary for Effective Maintenance Control System	p. 107
Work Control	p. 108
Cost Control	p. 109
Quality Control	p. 109
Plant Condition Control	p. 109
Effective Programs for Improving Maintenance Control	p. 110
Emergency Maintenance	p. 110
Reliability Improvement	p. 110
Total Productive Maintenance	p. 111
Computerized Maintenance Management and Information Technology	p. 111
Summary	p. 112
References	p. 112
Guidelines for Budgeting and Costing Planned Maintenance Services	p. 115
Introduction	p. 115
An Overview of Budgeting and Costing Systems	p. 116
Budgeting Systems	p. 116
Costing Systems	p. 117
Proposed Budgetary System	p. 118
Planned Maintenance Operating Budget	p. 118
Financial Budget	p. 119
The Budget Cycle	p. 120
Top Management Support	p. 120
Budget Performance Reports	p. 122
Planned Maintenance Job Costing	p. 123
Standard Cost Elements of a Planned Maintenance Job	p. 123
Actual Cost Elements of a Planned Maintenance Job	p. 128
Total Cost of a Planned Maintenance Job	p. 129
Planned Maintenance Job Cost Variances	p. 129
Significant Cost Variances	p. 130
Summary and Conclusions	p. 131
References	p. 132
Simulation Based Approaches for Maintenance Strategies Optimization	p. 133
Introduction	p. 133
Reliability Models Estimation	p. 134
Regression and ML Methods	p. 134
Uncertainty Affecting Reliability Model	p. 136
Maintenance Performance	p. 138
Availability Model	p. 138
Costs Model	p. 139
Simulation Based Maintenance Framework	p. 141
Toward a Unified Framework	p. 141
Maintenance Strategies	p. 142
Uncertainty Affecting Maintenance Performances	p. 146
A Case Study	p. 148
Conclusion	p. 152
References	p. 152
Maintenance Planning and Scheduling
Maintenance Forecasting and Capacity Planning	p. 157
Introduction	p. 157
Forecasting Basics	p. 158
Qualitative Forecasting Techniques	p. 159
The Delphi Method	p. 160
Quantitative Forecasting Techniques	p. 161
Simple Moving Averages	p. 161
Weighted Moving Average	p. 162
Regression Analysis	p. 163
Exponential Smoothing	p. 165
Seasonal Forecasting	p. 167
Box-Jenkins Time Series Models	p. 171
Error Analysis	p. 172
Forecasting Maintenance Workload	p. 173
Maintenance Capacity Planning	p. 175
Deterministic Approaches for Capacity Planning	p. 176
Modified Transportation Tableau Method	p. 176
Mathematical Programming Methods	p. 179
Stochastic Techniques for Capacity Planning	p. 182
Queuing Models	p. 182
Stochastic Simulation	p. 186
Summary	p. 188
References	p. 189
Integrated Spare Parts Management	p. 191
Introduction	p. 191
Spare Parts Identification and Classification	p. 192
Determination of the Required Quantity of Spare Parts	p. 193
Recommendations	p. 193
Reliability and Availability Based Procedures	p. 193
Forecasting Procedure	p. 198
Simulation	p. 200
Inventory Control Policies	p. 201
Model with Known and Constant Demand and Lead-time (EOQ Model)	p. 202
Model with Constant Demand and Perishable Items	p. 202
Model with Random Demand and Lead-time	p. 203
Joint Maintenance and Provisioning Strategies	p. 204
Joint Replacement and Ordering Policy for a Spare Unit (One Unit Provisioning)	p. 205
Joint Replacement and Multiple Spare Parts Ordering Policy (Batch Provisioning)	p. 207
Inventory and Maintenance Policies for Reconditioned Spare Parts	p. 209
Age of Recovered Parts to be Used for Replacement Actions	p. 209
Review of Inventory Control Policies with Random Returns	p. 213
Collaborative Management of Spare Parts	p. 213
Access to Documentation and Knowledge Bases	p. 213
Lead-time Reduction	p. 214
Virtually Centralized Spare Parts Stock (Inventory Pooling)	p. 214
Joint Replenishment of Spare Parts	p. 216
Conclusion	p. 218
References	p. 218
Turnaround Maintenance	p. 223
Introduction	p. 223
Turnaround Initiation	p. 225
Work Scope	p. 226
Long Lead Time Resources	p. 227
Contractors	p. 228
TAM Planning	p. 228
TAM Organization	p. 229
Site Logistics	p. 230
TAM Budget	p. 230
Quality and Safety Plans	p. 231
Quality Plan	p. 231
Safety Plan	p. 231
TAM Communication Procedures	p. 232
TAM Execution	p. 233
TAM Closing and Final Report	p. 233
Conclusion	p. 234
References	p. 235
Maintenance Planning and Scheduling	p. 237
Introduction	p. 237
Strategic Planning in Maintenance	p. 240
Medium Range Planning	p. 244
Short Range Planning	p. 247
Maintenance Scheduling	p. 247
Elements of Sound Scheduling	p. 249
Maintenance Job Priority System	p. 249
Scheduling Techniques	p. 250
Gantt Charts and Scheduling Theory	p. 250
Project Scheduling	p. 253
Critical Path Method	p. 256
Program Evaluation Review Techniques (PERT)	p. 258
Scheduling Using Computers	p. 260
Summary	p. 260
References	p. 261
Models for Production and Maintenance Planning in Stochastic Manufacturing Systems	p. 263
Introduction	p. 263
Problem Statement and Preliminary Results	p. 264
Dynamic Programming Approach	p. 274
Linear Programming Approach	p. 280
Conclusion	p. 295
References	p. 296
Maintenance Strategies
Inspection Strategies for Randomly Failing Systems	p. 303
Introduction	p. 303
Notation	p. 304
Basic Inspection Model	p. 305
Problem Definition	p. 305
Working Assumptions and Mathematical Model	p. 306
Extensions of the Basic Model	p. 308
Inspection Models for Single Component Systems	p. 308
Inspection Models for Multi-component Systems	p. 318
Failure Tree Method Based Strategies	p. 318
Cases of Cold and Hot Stand-by Systems with Known and Partially Known Lifetime Distributions	p. 319
Case of Systems with Components Failure Dependency	p. 320
Conditional Maintenance Models	p. 321
Conditional Maintenance Models for Single Component Systems	p. 321
Conditional Maintenance Models for Multi-Component Systems	p. 329
Conclusion	p. 331
References	p. 332
System Health Monitoring and Prognostics - A Review of Current Paradigms and Practices	p. 337
Maintenance Strategies: Motivations for Health Monitoring	p. 337
Health Monitoring Paradigms	p. 340
Health Monitoring Tools and Techniques	p. 343
Reliability-based Maintenance	p. 343
Model-based Approach to FDI	p. 344
Signal-based FDI	p. 346
Statistical FDI/Maintenance	p. 347
Case Studies in System Monitoring and Control	p. 347
Organizations and Standards	p. 352
Summary and Research Directions	p. 356
References	p. 357
Applied Maintenance Models	p. 363
Introduction	p. 363
Missile Maintenance	p. 365
Expected Cost	p. 366
Optimal Inspection Policies	p. 367
Numerical Illustrations	p. 370
Phased Array Radar Maintenance	p. 373
Cyclic Maintenance	p. 374
Delayed Maintenance	p. 377
Numerical Illustrations	p. 379
Self-diagnosis for FADEC	p. 380
Double Module System	p. 381
Triple Module System	p. 384
N Module System	p. 386
Numerical Illustrations	p. 386
Co-generation System Maintenance	p. 387
Model and Assumptions	p. 388
Analysis	p. 389
Optimal Policy	p. 390
Numerical Illustration	p. 391
References	p. 392
Reliability Centered Maintenance	p. 397
Introduction	p. 397
RCM Philosophy	p. 400
RCM Principles and Key Features	p. 400
RCM Goals and Benefits	p. 401
System, System Boundary, Interfaces and Interactions	p. 401
Failure and its Nature	p. 404
RCM Methodology	p. 405
Selecting Systems Selection and Collecting Information	p. 405
System Boundary Definition	p. 407
System Description and Functional Block Diagram	p. 407
System Functions and Functional Failure	p. 410
Failure Mode and Effective Analysis (FEMA)	p. 410
Logic or Decision Tree Analysis (LTA)	p. 411
Task Selection	p. 411
RCM Implementation	p. 411
Organizational Factors	p. 412
RCM Teams	p. 413
Scheduling Consideration and Training	p. 413
Conclusion	p. 414
References	p. 414
Total Productive Maintenance	p. 417
Introduction to TPM	p. 417
Evolution Towards TPM	p. 420
Need to TPM	p. 422
Basic Elements of TPM	p. 424
Roadmap for TPM Implementation	p. 429
An Ideal TPM Methodology	p. 435
Introduction Phase (Phase I)	p. 435
TPM Initiatives Implementation Phase (Phase II)	p. 445
Standardization Phase (Phase III)	p. 451
Barriers in TPM Implementation	p. 453
Success Factors for Effective TPM Implementation	p. 456
Summary	p. 458
References	p. 458
Warranty and Maintenance	p. 461
Introduction	p. 461
Maintenance Modelling	p. 462
Reliability	p. 462
Types of Maintenance	p. 462
Failure Modelling	p. 462
Warranties	p. 465
Base Warranties	p. 465
Classification of Base Warranties	p. 466
Warranty Servicing Cost Analysis	p. 466
Extended Warranties	p. 467
Link Between Warranty and Maintenance	p. 467
Taxonomy for Classification	p. 467
Warranty Servicing Involving Only CM	p. 468
Warranty Servicing Involving Both CM and PM	p. 469
Maintenance Logistics for Warranty Servicing	p. 470
Strategic Issues	p. 471
Tactical and Operational Issues	p. 472
Outsourcing of Maintenance for Warranty Servicing	p. 474
Agency Theory	p. 474
Conclusions and Topics for Future Research	p. 476
References	p. 476
Delay Time Modeling for Optimized Inspection Intervals of Production Plant	p. 479
Introduction	p. 479
The DT Concept and Modeling Characteristics	p. 480
The DT Models for Complex Plant	p. 483
The Down Time/Cost Model	p. 483
Modeling E[Nf((i-1)T, iT)] and E[Ns (iT)] Under the Assumption of Perfect Inspections	p. 484
Modeling E[Nf((i-1)T, iT)] and E[Ns (iT)] Under the Assumption of Imperfect Inspections	p. 485
Delay Time Model Parameters Estimation	p. 487
Introduction	p. 487
Complex System - Parameter Estimation	p. 488
A Case Example	p. 493
Other Developments in DT Modeling and Future Research Directions	p. 496
References	p. 497
Integrated E-maintenance and Intelligent Maintenance Systems	p. 499
Introduction	p. 499
Condition-based Maintenance Technology and the State of Development	p. 501
Integrated E-maintenance Solutions and Current Status	p. 503
Technical Framework for E-maintenance	p. 507
Watchdog Agent-based Intelligent Maintenance Systems	p. 511
R2M-PHM Platform	p. 511
System Architecture	p. 512
Toolbox for Multi-sensor Performance Assessment and Prognostics	p. 514
Maintenance Decision Support System	p. 518
Technology Integration for Advanced E-maintenance	p. 520
Generic ICT Interface	p. 520
Generic Interface Requirements for Watchdog Agents	p. 525
Systems-user Interface Needs	p. 528
Some Industrial Applications	p. 528
E-maintenance Solutions for Complex Industrial Assets	p. 528
Watchdog Technology for Product Life-cycle Design and Management	p. 532
Watchdog Technology to Trouble-shoot Bearing Degradation	p. 533
Challenges of E-maintenance Application Solutions	p. 536
Conclusion	p. 538
References	p. 539
Maintainability and System Effectiveness
Maintainability and System Effectiveness	p. 547
Introduction	p. 547
The Concept of Maintainability	p. 550
Maintainability Impact on System Effectiveness	p. 552
Maintainability Impact on Safety	p. 555
Undesirable Maintainability Practices	p. 558
Desirable Maintainability Practices	p. 559
Maintainability Analysis	p. 561
Measures of Maintaniability	p. 565
Maintenance Labour-hour Factors	p. 568
Maintenance Frequency Factors	p. 569
Maintenance Cost Factors	p. 570
Related Maintenance Factors	p. 570
Empirical Data and Maintainability Measures	p. 571
Possible Approaches to Analysis of Existing Data	p. 571
Parametric Approach to Maintainability Data	p. 572
Distribution Approach to Maintainability Data	p. 572
Distribution Approach	p. 575
Maintainability Engineering Predictions	p. 576
Introduction	p. 577
Concept of the Maintainability Block Diagram	p. 577
Derivation of the Expression for the Maintainability Function	p. 580
Maintainability Characteristics for Different Design Options	p. 585
Maintainability Engineering Management	p. 592
Role of the Maintainability Engineering Management Function	p. 593
MEMF Opportunities	p. 594
MEMF Obstacles	p. 594
Design Methods for Attaining Maintainability	p. 596
Maintainability Engineering Management - Lessons Learned	p. 603
Concluding Remarks	p. 607
References	p. 610
Maintenance Safety, Environment and Human Error
Safety and Maintenance	p. 613
Setting the Scene	p. 613
Definitions	p. 615
Maintenance	p. 615
Safety	p. 616
Hazard	p. 616
Stimuli	p. 616
Accident	p. 616
The Maintenance Link to Safety	p. 617
The Role of Maintenance	p. 617
Safety During Maintenance	p. 620
Maintenance for Safety	p. 622
Human Errors in Maintenance	p. 625
Accident Causation Theories vs Maintenance	p. 626
Maintenance Policies and Concepts vs Safety	p. 629
Definitions	p. 630
Maintenance Actions	p. 630
Maintenance Policies	p. 631
Maintenance Concepts	p. 633
Maintenance Safety and Accident Prevention	p. 636
Methods of Accidents and Hazards Avoidance in Maintenance	p. 637
Analytical Approach	p. 637
The Engineering Approach	p. 638
Safety Culture	p. 641
Safety Legislations	p. 642
Safety Measurement	p. 643
References	p. 646
Maintenance Quality and Environmental Performance Improvement: An Integrated Approach	p. 649
Introduction	p. 649
Maintenance Quality	p. 650
Improving Maintenance Quality	p. 650
Benchmarking and Quality	p. 651
Maintenance Audit	p. 655
Improving Maintenance Quality Based on Stakeholder Feedback	p. 656
Lean Manufacturing - Maintenance Quality Relationship	p. 656
Basic Environmental Measure	p. 656
Integrated Approach	p. 660
Conclusion	p. 663
References	p. 663
Industrial Asset Maintenance and Sustainability Performance: Economical, Environmental, and Societal Implications	p. 665
Introduction	p. 665
Industrial Activities and Sustainability Trends	p. 666
Sustainability Performance in Perspective	p. 668
Sustainability Performance Framework: From Business to Asset	p. 671
Defining Maintenance Custodianship Within an Asset's Sustainability Performance	p. 676
Generic Maintenance Impact Management Process	p. 683
Adapting an Effective Asset Maintenance Practice for Sustainability	p. 686
Conclusion	p. 689
References	p. 689
Human Reliability and Error in Maintenance	p. 695
Introduction	p. 695
Terms and Definitions	p. 695
Human Reliability and Error in Maintenance-Related Facts, Figures, and Examples	p. 696
Occupational Stressors, Human Performance Effectiveness, and Human Performance Reliability Function	p. 697
Human Error Occurrence Ways, Consequences, and Classifications, and Maintenance Error in System Life Cycle	p. 700
Reasons for the Occurrence of Human Error in Maintenance and Top Human Problems in Maintenance	p. 701
Mathematical Models for Performing Maintenance Error Analysis in Engineering Systems	p. 702
Model I	p. 703
Model II	p. 705
Useful Guidelines to Reduce the Occurrence of Human Error in Maintenance	p. 707
References	p. 709
Human Error in Maintenance - A Design Perspective	p. 711
Introduction	p. 711
Human Error in Aircraft Maintenance	p. 712
Significance of Maintenance Error	p. 713
Design Impact	p. 717
Analysis Required for Design Solutions	p. 718
Maintenance Tasks	p. 721
Maintenance Errors	p. 722
Causal Factors	p. 724
Design Strategies and Principles	p. 726
Appreciate the Maintainer's Perspective of the Aircraft	p. 729
Design for the Aircraft Maintenance Environment	p. 729
Protect the Aircraft and Protect the Maintainer	p. 731
Avoid Complexity of Maintenance Tasks	p. 732
Enable Adequate Maintenance Access	p. 732
Positively Standardise and Positively Differentiate	p. 733
Build Error Detection into the Maintenance Process	p. 734
Conclusion	p. 734
References	p. 735
Index	p. 737
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