Maintenance Systems and Documentation

By: Anthony Kelly

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Paperback | 10 May 2006

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264 Pages

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24 x 17 x 1.5

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Managing Systems and Documentation addresses the main systems necessary for the successful operation of a maintenance organization, such as performance control, work control and documentation. It shows how they can be modelled, their function and operating principles, and the main problems encountered in operation. It is the third of three stand-alone companion books with the aim of providing better understanding of maintenance operations, in order to identify problems and prescribe effective solutions.

This is one of three stand-alone volumes designed to provide maintenance professionals in any sector with a better understanding of maintenance management, enabling the identification of problems and the delivery of effective solutions.

* The third of three stand-alone companion books, focusing on the main systems necessary for the successful operation of a maintenance organization
* Covers the maintenance of plant, production and operations assets in industry and service sectors, including manufacturing, food and process engineering, minerals and mining, transport, power and IT
* Includes review questions, exercises and case studies
* Clearly specified objectives and learning outcomes are given for each chapter, including a route map to link each chapter to the rest of the topics covered

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You Can Find This Book In

Non-Fiction Engineering & Technology Technology in General Engineering in General Business & Management Management & Management Techniques Management of Specific Areas Production of Quality Control Management Kids & Children's Books Educational Material Technology Educational Material Management of Real Estate

Industrial Chemistry & Manufacturing Technologies

Preface	p. xi
Acknowledgments	p. xiii
Author's biography	p. xv
Introductory chapters	p. 1
A business-centered approach to maintenance systems	p. 3
Introduction	p. 4
Business-centered maintenance	p. 4
An example of the application of BCM: background	p. 6
Part A: Audit of the FPP maintenance department	p. 7
Maintenance objectives	p. 8
Life plans and preventive schedule	p. 9
Workload	p. 11
Maintenance organization	p. 12
Maintenance work planning	p. 16
Maintenance control system	p. 19
Maintenance documentation	p. 23
Audit summary	p. 25
Part B: An alternative maintenance strategy for continuous operation	p. 25
Part C: A longer-term view of organizational change	p. 26
The strategic thought process	p. 27
Introduction to maintenance management systems	p. 33
The company expressed as a hierarchic systems model	p. 34
Identifying the maintenance systems	p. 36
Budgeting and control	p. 39
Maintenance budgeting	p. 41
Introduction	p. 42
Maintenance budgeting	p. 42
The budgeting procedure	p. 45
Maintenance management control	p. 53
Introduction	p. 54
The basics of maintenance management control	p. 55
Principles of maintenance management control	p. 56
The control of overall maintenance performance	p. 57
The control of maintenance effectiveness (the control of plant reliability)	p. 61
Reactive control of plant reliability	p. 61
Pro-active control of unit reliability	p. 62
The control of organizational efficiency	p. 63
Incorporating systems into the organization	p. 64
Published methods for measuring maintenance performance	p. 67
The use of indices of maintenance performance for inter-firm comparisons	p. 67
Human factors and data collection	p. 67
Work planning and work control	p. 71
Short-term work planning and control	p. 73
Introduction	p. 74
The fundamentals of work planning	p. 74
Modeling the operation of a short-term work planning system	p. 75
The shift work planning system	p. 79
The weekend work planning system	p. 81
Feedback of maintenance data for control	p. 82
Comments on work planning and work control	p. 83
Guidelines for the design of work planning systems	p. 84
Safety aspects	p. 88
Management of plant turnarounds - Part 1: Network analysis	p. 91
Introduction	p. 92
Terms, concepts and definitions in network analysis	p. 93
The network planning procedure	p. 96
Data collection	p. 97
Constructing the logic diagram	p. 97
Establishing the critical path, floats and overhaul time	p. 99
Deriving a bar chart from the network	p. 101
Resource histograms	p. 102
Comments	p. 103
Management of plant turnarounds - Part 2: Turnaround methodology	p. 109
Introduction	p. 110
Phase 1: Initiating the turnaround	p. 110
Forming a policy team and appointing a turnaround manager	p. 110
Key policy decisions for the initiation phase	p. 113
Selecting a preparation team	p. 114
Collecting the job lists and other data	p. 114
Phase 2: Preparing the turnaround	p. 114
Analyzing and validating the workscope	p. 114
Freezing the worklist	p. 116
Preparing task specifications	p. 116
Identifying pre-shutdown work	p. 116
Defining contractor work packages and selecting contractors	p. 120
Creating the work schedule	p. 120
Techniques for creating a schedule	p. 120
Optimizing the schedule	p. 123
Forming the turnaround organization	p. 123
Defining the site logistics	p. 125
Formulating a cost estimate	p. 125
Formulating a safety plan	p. 126
Formulation of the quality plan	p. 127
Briefing of all turnaround personnel	p. 127
Phase 3: Executing the turnaround	p. 128
The shutdown of the plant	p. 128
Carrying out the turnaround tasks	p. 129
Defining and costing the extra work	p. 129
Defining and costing additional work	p. 129
Monitoring progress, productivity, safety, quality and expenditure	p. 129
Starting up the plant	p. 130
Phase 4: Terminating the turnaround	p. 130
Spare parts management	p. 135
Spare parts management	p. 137
Introduction	p. 138
Outline of the stores operation	p. 139
Inventory policy	p. 142
Inventory policy for fast-moving spares	p. 142
Inventory policies for the control of slow-moving spares	p. 145
Management of repairable equipment (rotables)	p. 150
Introduction	p. 150
The rotable system	p. 150
Rotable inventory policy: the theory	p. 153
Rotable inventory policy: in practice	p. 155
Inventory policy guidelines	p. 155
Stores documentation	p. 156
Stores organization	p. 160
Stores and rotable performance indices	p. 161
Summary	p. 162
Documentation	p. 165
Maintenance documentation systems: what they are and how they work	p. 167
Introduction	p. 168
A functional model	p. 168
Plant inventory (Module 1)	p. 170
Information base (Element 2)	p. 172
Preventive maintenance schedule (Module 3)	p. 177
Condition monitoring (Module 4)	p. 179
Short-term work planning (Module 5)	p. 180
Long-term work planning (Module 6)	p. 182
Maintenance control (Module 7)	p. 185
Summary	p. 187
Computerized maintenance information systems: their uses and problems	p. 189
Introduction	p. 190
Computerized documentation: historical background	p. 190
The benefits of computerized maintenance information systems	p. 193
The problems with computerized maintenance information systems	p. 195
Summary	p. 196
Case study	p. 199
Case study: Maintenance audit of an agricultural chemical plant	p. 201
Introduction	p. 202
An overview of Fertec A	p. 202
Objectives	p. 203
Comments on objectives	p. 204
Maintenance strategy	p. 206
Plant-operating characteristics	p. 206
Ammonia plant maintenance strategy	p. 206
Maintenance organization	p. 212
Introduction	p. 212
The maintenance resource structure	p. 212
The maintenance administrative structure	p. 215
Work planning systems	p. 217
Short-term work planning, scheduling and control	p. 217
The planning of the major shutdowns	p. 223
Spare parts management	p. 225
Introduction	p. 225
Outline of the stores organization and systems	p. 225
Maintenance control	p. 226
The control of overall maintenance performance	p. 226
The control of organizational efficiency	p. 226
The control of maintenance effectiveness (plant reliability control)	p. 227
Documentation	p. 227
Comments and recommendations	p. 228
Weibull analysis	p. 229
Weibull analysis of item lifetime	p. 229
Weibull probability paper	p. 232
A Weibull analysis of a large and complete sample of times-to-failure	p. 232
Index	p. 235
Table of Contents provided by Ingram. All Rights Reserved.

Maintenance Systems and Documentation

At a Glance

Paperback

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