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100 Years of Maintenance and Reliability : Practical Lessons from Three Lifetimes at Process Plants - Venkat Narayan

100 Years of Maintenance and Reliability

Practical Lessons from Three Lifetimes at Process Plants

Hardcover

Published: 23rd March 2012
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  • Provides a logical organization with chapters grouped into six broad headings, enabling readers to choose the order in which they wish to absorb the lessons, which are based on the Shewhart-Deming Continuous Improvement cycle.
  • In addition to the Plan-Schedule-Execute-Analyze elements, the authors have added Leadership and People to complete the suite.
  • Each chapter has broadly similar sections, beginning with a Background to the events, going on to describe the key elements of the approach, and ending with Lessons and Principles.
  • Underlying theories, philosophies or even detailed descriptions of methods are stripped out of the main chapters and described in Appendices, so that only those readers who wish to delve into details may do so.
  • Contains a Book Summary which draws all the principles and lessons together, and gives references to the relevant chapters.
  • Copiously illustrated, with charts, diagrams and tables which relate closely to the text.

" This book is an essential tool to help pass on the wealth of knowledge of best practices to future generations of maintenance leaders. My only hope is that lots of professionals read it so that many companies and economies reap the benefits of these solid practices. "

Joel Leonard
The Maintenance Evangelist
MPACT Learning Center
"


""The book represents a great wealth of practical experience on many topics ... an essential primer on maintenance topics ... from a practical point of view. I will make this required reading by the SAMI maintenance consultants. There is certainly food for thought even for the most experienced manager." "

S. Bradley Peterson
President
Strategic Asset Management, Inc.


" This is a must read for people who have to struggle with the day-to-day problems of plant life. If you have a subordinate field position in a manufacturing facility, this book will reveal why bosses do the things they do. If you are in a supervisory or management role, this book will help you steer your career. "

Charles J. Latino
CEO and President
Reliability Center, Inc."


I have written numerous maintenance and reliability books myself and when I first took a quick glance at the book I did not see the real value in it until I sat down and read it. What these authors did was take their real world experience and join knowledge to make a great book. If you are experiencing anxiety in your plant or just curious how to make your operation run more efficiently I highly recommend this book. Good job guys. This is the first book I have ever read like this. I love it. ---Ricky Smith, CMRP"


I read the book from the perspective of a 'non-technical' reader and think that it is a fund of valuable knowledge and experience.

I find it very well organized. The summary at the end, the background, lessons and principles in each chapter made it very easy for me to follow and flow with the content. I particularly liked the 'marriage' of time-tested management principles and technical strategies with a people-oriented approach. The fact that several 'people-failures' are really 'process-failures' rings true. I like the emphasis on communication, sharing, and alignment of the vision with and through the ranks of all involved personnel. Kudos to the authors for sharing their life long experience through this book... --- Ayesha Chopra, Trainer, Seminar Leader and Co-author ''Secretary's Factomatic''


This book is an essential tool to help pass on the wealth of knowledge of best practices to future generations of maintenance leaders. My only hope is that lots of professionals read it so that many companies and economies reap the benefits of these solid practices.

Joel Leonard
The Maintenance Evangelist
MPACT Learning Center

"

This is a must read for people who have to struggle with the day-to-day problems of plant life. If you have a subordinate field position in a manufacturing facility, this book will reveal why bosses do the things they do. If you are in a supervisory or management role, this book will help you steer your career.

Charles J. Latino
CEO and President
Reliability Center, Inc.

"

I read the book from the perspective of a 'non-technical' reader and think that it is a fund of valuable knowledge and experience.

I find it very well organized. The summary at the end, the background, lessons and principles in each chapter made it very easy for me to follow and flow with the content. I particularly liked the 'marriage' of time-tested management principles and technical strategies with a people-oriented approach. The fact that several 'people-failures' are really 'process-failures' rings true. I like the emphasis on communication, sharing, and alignment of the vision with and through the ranks of all involved personnel. Kudos to the authors for sharing their life long experience through this book... --- Ayesha Chopra, Trainer, Seminar Leader and Co-author ''Secretary's Factomatic''


-This book is an essential tool to help pass on the wealth of knowledge of best practices to future generations of maintenance leaders. My only hope is that lots of professionals read it so that many companies and economies reap the benefits of these solid practices.-

Joel Leonard
-The Maintenance Evangelist-
MPACT Learning Center


-The book represents a great wealth of practical experience on many topics ... an essential primer on maintenance topics ... from a practical point of view. I will make this required reading by the SAMI maintenance consultants. There is certainly food for thought even for the most experienced manager.-

S. Bradley Peterson
President
Strategic Asset Management, Inc.


-This is a must read for people who have to struggle with the day-to-day problems of plant life. If you have a subordinate field position in a manufacturing facility, this book will reveal why bosses do the things they do. If you are in a supervisory or management role, this book will help you steer your career.-

Charles J. Latino
CEO and President
Reliability Center, Inc.


I have written numerous maintenance and reliability books myself and when I first took a quick glance at the book I did not see the real value in it until I sat down and read it. What these authors did was take their real world experience and join knowledge to make a great book. If you are experiencing anxiety in your plant or just curious how to make your operation run more efficiently I highly recommend this book. Good job guys. This is the first book I have ever read like this. I love it. --- Ricky Smith, CMRP


"This book is an essential tool to help pass on the wealth of knowledge of best practices to future generations of maintenance leaders. My only hope is that lots of professionals read it so that many companies and economies reap the benefits of these solid practices."

Joel Leonard
"The Maintenance Evangelist"
MPACT Learning Center


"The book represents a great wealth of practical experience on many topics ... an essential primer on maintenance topics ... from a practical point of view. I will make this required reading by the SAMI maintenance consultants. There is certainly food for thought even for the most experienced manager."

S. Bradley Peterson
President
Strategic Asset Management, Inc.


"This is a must read for people who have to struggle with the day-to-day problems of plant life. If you have a subordinate field position in a manufacturing facility, this book will reveal why bosses do the things they do. If you are in a supervisory or management role, this book will help you steer your career."

Charles J. Latino
CEO and President
Reliability Center, Inc.

Forewordp. vii
Introduction
Introduction & Navigation Guidep. 3
The Locationsp. 7
Leadership
Creating the Visionp. 15
Setting Objectivesp. 23
Changing Paradigms with Leadership and Expertisep. 29
Applying Best Business Practicesp. 38
Evaluating Contractors' Unit Ratesp. 57
Benchmarkingp. 65
People
Staffing levelsp. 79
Integrating Inspection and Degradation Strategiesp. 87
Technician Training Challengep. 95
Competence Profilesp. 100
Operators & Maintainersp. 109
Building a Reliability Culturep. 119
Managing Surplus Staffp. 122
Retraining Surplus Staffp. 129
Plan
Integrated Planningp. 135
Critical Path Planning Capabilityp. 141
Shutdown Managementp. 144
Electrical Maintenance Strategiesp. 153
Minor Maintenance by Operatorsp. 162
Relocating Machine Toolsp. 168
Painting Contract Strategyp. 183
Schedule
Long Look-Ahead Planp. 191
Workload Managementp. 196
Infrastructure Maintenancep. 200
Workflow Managementp. 205
Execute
Trip Testingp. 217
Work the Planp. 221
Keeping to Schedulep. 229
Operators as a Maintenance Resourcep. 235
Overtime Controlp. 240
Managing Contractorsp. 245
Analyze
Reliability Engineering in New Projectsp. 257
Computing Reliability Datap. 265
Turnaround Performance Improvementsp. 272
Reducing Shutdown Durationp. 282
A Small Matter of Cleaningp. 291
Motor Maintenance Regimesp. 296
Boiler Feed-Water Pump Sealsp. 303
Cooling Water Pump Failuresp. 309
Heater Outlet Flue Gas Dampersp. 319
Laboratory Oven Failuresp. 325
Pump Reliabilityp. 335
Book Summaryp. 342
Glossaryp. 349
Indexp. 361
Table of Contents provided by Ingram. All Rights Reserved.

ISBN: 9780831133238
ISBN-10: 0831133236
Audience: Professional
Format: Hardcover
Language: English
Number Of Pages: 350
Published: 23rd March 2012
Publisher: Industrial Press Inc.,U.S.
Country of Publication: US
Dimensions (cm): 22.9 x 15.2  x 2.39
Weight (kg): 0.81