Computer-Managed Maintenance Systems, Second Edition

A Step-by-Step Guide to Effective Management of Maintenance, Labor, and Inventory

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By: Cato, Mobley

Hardcover

Published: 1st December 2001

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Description
Industry Reviews
Table of Contents
Product Details

Effective resource management and reliable equipment are essential for optimum plant performance. Computer-Managed Maintenance Systems goes beyond the simple selection and implementation of a CMMS. It also defines the changes in infrastructure, management philosophy and employee skills that must be implemented to gain maximum benefits from the CMMS. The book is designed to address the information needs of all levels of plant management.

In this new edition, the authors have added a chapter specifically on the latest technology, Application Solution Providers (ASP) that has revolutionized the way CMMS are used and the benefits they can offer to a business. This solution provides integrated software, hardware and networking technology along with Information Technology (IT) consulting services into an outsourced package. A new appendix on Key Performance Indicators has also been added.
Comprehensive, practical guide that covers selection, justification, and implementation of an effective CMMS in any facilityAll levels of plant management will find useful information in this step-by-step guideIncludes a new chapter on ASP technologies

The book is true to its name in that the step-by-step layout allows plant managers to all levels to follow the process from implementation to financial assessment. -Society of Operations Engineers

...contains useful appendicess that aid readers in benchmarking current status and selecting a CMMS vendor. -Society of Operations Engineers

Preface	p. x
Determining the Need and Selling the Program	p. 1
Determining the Need	p. 1
The New View of Maintenance Productivity	p. 1
Determining the Need for a CMMS	p. 2
How a CMMS Meets the Need	p. 3
What a CMMS Should Do for You	p. 6
What You Need in a CMMS	p. 7
Selling the Program	p. 9
Definition of a CMMS	p. 13
CMMS Functionality	p. 14
Equipment/Asset Records Creation and Maintenance	p. 14
Equipment/Asset Bills of Materials Creation and Maintenance	p. 14
Equipment/Asset and Work Order History	p. 14
Inventory Control	p. 15
Work Order Creation, Scheduling, Execution, and Completion	p. 15
Preventive Maintenance Plan Development and Scheduling	p. 16
Human Resources	p. 17
Purchasing and Receiving	p. 17
Invoice Matching and Accounts Payable	p. 17
Tables and Reports	p. 18
CMMS Databases or Files	p. 18
Equipment/Asset Identification and Specifications	p. 18
Equipment/Asset Hierarchies	p. 20
Equipment/Asset Bills of Materials	p. 22
Cross Reference of Inventory to Equipment/Asset "Where Used"	p. 23
Spare Parts and Stores Inventory	p. 24
Work Orders	p. 26
Preventive Maintenance Plans	p. 27
Repetitive Maintenance Plans	p. 27
Cost Accounting Data	p. 28
Work Order History	p. 28
Craft/Skill Data	p. 30
Purchase Requisitions	p. 30
Purchase Orders	p. 31
Who Uses a CMMS and How	p. 33
Maintenance	p. 33
Engineering	p. 40
Production	p. 42
Inventory Control	p. 44
Purchasing	p. 47
Accounting/Finance	p. 48
Executive Management	p. 49
What a CMMS Will Do	p. 50
Maintain, Sort, Summarize, and Display Data	p. 50
Automate and Control a Reliable Preventive Maintenance Program	p. 51
Automate and Control a Reliable Inventory Replenishment Program	p. 51
Provide Accurate Job Scheduling Based Upon Resource Availability	p. 52
Maintain Accurate Historical Records	p. 52
Improve Planning	p. 52
Improve Labor Productivity	p. 53
What a CMMS Will Not Do	p. 53
Replace a Maintenance Manager	p. 53
Replace Planners	p. 54
Assign Work	p. 54
Bring Order to Chaos	p. 55
Improve Reliability and Quality	p. 55
CMMS Justification	p. 56
Needs Analysis	p. 57
Functional Requirements for Effective Maintenance	p. 58
Identifying Limiting Factors	p. 58
Prepare Flow Charts of Existing Activities	p. 59
Determine Inputs/Outputs	p. 59
Document Existing Job Profiles	p. 60
Determine Volume and Frequency	p. 60
Prioritize and Categorize Activities	p. 60
Identify Opportunities for Improvement	p. 60
Prepare Flow Charts of Proposed Changes	p. 61
Determine Inputs/Outputs	p. 61
Document Proposed Job Profiles	p. 61
Determine the Number of Work Stations	p. 61
Determine Specific Organizational Requirements	p. 64
Maintenance Organizations	p. 67
Centralized Maintenance	p. 67
Assigned Maintenance	p. 68
Labor Distribution	p. 68
Cost-Benefit Analysis	p. 69
Estimating the Cost of Implementation	p. 70
Typical Benefits of Effective Maintenance Management	p. 70
Six Keys to Selling Your CMMS Program	p. 75
Do Your Homework	p. 75
Develop Concise Goals and Objectives	p. 76
Know Your Audience	p. 76
Forget You Are in Maintenance	p. 78
Develop a Detailed Implementation Plan	p. 79
Get Absolute Buy-In	p. 80
CMMS Vendor Selection	p. 81
Developing the Requirements Document	p. 82
Determining the Short List of Vendors	p. 85
System Evaluation	p. 86
Request for Proposal	p. 88
Proposal Evaluation	p. 88
Contract Negotiation	p. 89
Fully Understand the Proposed System	p. 90
Verify the Proposed System	p. 90
Understand the Competitive Costs for Systems	p. 90
Understand the Competitive Cost for Services	p. 91
Negotiate a Fair Price	p. 92
Do Not Be Intimidated by the Vendor	p. 93
Project Implementation	p. 94
Project Plan Development	p. 94
Infrastructure Requirements	p. 95
Labor Requirements	p. 98
Training Requirements	p. 99
Project Schedule	p. 101
System Installation	p. 102
Hardware Installation	p. 102
Software Installation	p. 104
Database Development	p. 105
Equipment/Asset Numbering Logic	p. 106
Inventory/Spares Numbering Logic	p. 108
Data Acquisition	p. 109
Data Entry	p. 110
Integrating a CMMS with Other Systems	p. 111
Inventory	p. 113
Purchasing	p. 114
Invoice Matching and Accounts Payable	p. 114
Cost Accounting and General Ledger	p. 115
Payroll	p. 116
Graphics	p. 117
Project Tracking	p. 117
Predictive Maintenance Systems	p. 117
CMMS and Client Server	p. 119
Background	p. 119
Client Server Concept	p. 120
Maintenance Requirements	p. 123
Why a CMMS Fails	p. 125
Partial Implementation	p. 126
Lack of Resources	p. 127
Fragmentation of Effort	p. 127
Staff Overload or Not Enough Staff	p. 128
Inappropriate Expectations	p. 128
Lack of Behavioral Expectations	p. 129
Treating Computers as Deliverables	p. 129
Confrontation Instead of Collaboration	p. 129
Poor Communication	p. 130
Lack of Expertise	p. 130
Reliance on Consultants	p. 131
Modification of the CMMS	p. 131
Work Culture Restrictions	p. 132
How to Assure Success	p. 133
Plant Culture	p. 133
Sales and Marketing	p. 134
Production	p. 134
Procurement	p. 135
Maintenance	p. 136
Information Systems	p. 136
Other Plant Functions	p. 137
Plant Size Considerations	p. 137
Small Plants	p. 137
Large Plants	p. 139
The Application Service Provider: Internet Based Solution	p. 141
Definition of an Application Service Provider and Their Internet Solution	p. 142
Benefits of Using an ASP	p. 143
Risk Associated With an ASP Solution	p. 145
Selecting an ASP	p. 147
Comparison of CMMS Systems	p. 149
Typical CMMS Data Fields	p. 160
Sample CMMS Vendor Evaluation Form	p. 163
Benchmark Criteria for World-Class Organizations	p. 167
Work Measurement: Key Performance Indicators	p. 170
Index	p. 177
Table of Contents provided by Syndetics. All Rights Reserved.

ISBN: 9780750674737
ISBN-10: 0750674733
Audience: Professional
Format: Hardcover
Language: English
Number Of Pages: 208
Published: 1st December 2001
Publisher: Elsevier Science & Technology
Country of Publication: GB
Dimensions (cm): 23.4 x 15.6 x 1.91
Weight (kg): 0.45
Edition Number: 2
Edition Type: Revised