Managing Maintenance Resources

By: Anthony Kelly

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Paperback | 10 May 2006

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312 Pages

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23.5 x 17 x 1.5

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Managing Maintenance Resources shows how to reduce the complexity involved in engineering, or re-engineering, a maintenance organization. It recognises that this is a complex problem involving many inter-related decisions - such as whether or not resources should be centralized, contractor alliances be entered into or flexible working be adopted. This book provides a unique approach to modeling maintenance-production organizations. It enables the identification of problems and delivers guidelines to develop 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 second of three stand-alone companion books, focusing on reducing the complexity of organizational design
* 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

Industry Reviews

"The book provides a unique approach to modeling maintenance-production organizations. It enables the identification of problems and delivers guidelines to develop effective solutions. The book is one of three standalone volumes on maintenance management." --IE Industrial Engineer, Norcross, GA December 2006

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Preface	p. xi
Acknowledgments	p. xiii
Author's biography	p. xv
Introductory chapters	p. 1
A business-centered approach to maintenance organization	p. 3
Introduction	p. 4
Business-centered maintenance	p. 4
An example of the application of BCM: background	p. 5
Part A: Audit of the FPP maintenance department	p. 7
Maintenance objectives	p. 7
Life plans and preventive schedule	p. 8
Workload	p. 11
Maintenance organization	p. 13
Maintenance work planning	p. 16
Maintenance control system	p. 18
Maintenance documentation	p. 19
Audit summary	p. 21
Part B: An alternative maintenance strategy for continuous operation	p. 22
Part C: A long-term view of organizational change	p. 23
The strategic thought process	p. 23
Maintenance organization in outline	p. 29
Introduction	p. 30
Modeling the organization	p. 31
Factors influencing the design of the maintenance organization	p. 33
The maintenance workload	p. 39
Introduction	p. 40
Categorization of the maintenance workload	p. 40
Mapping the workload	p. 43
First-line workload	p. 43
Second-line workload	p. 45
Third-line workload	p. 46
Forecasting the maintenance workload	p. 46
First-line workload	p. 47
Second-line workload	p. 47
Third-line workload	p. 48
Case studies in categorizing and mapping the maintenance workload	p. 49
Ammonia plant	p. 49
Chemical plant	p. 49
Agricultural chemicals	p. 50
Alumina refining	p. 51
Maintenance organizational concepts, trends and mapping	p. 55
Maintenance resource structure	p. 57
Introduction	p. 58
Mapping the resource structure	p. 58
Resource characteristics	p. 62
Manpower	p. 63
Spare parts	p. 63
Tools	p. 64
Information	p. 64
A decision model for the design or modification of a resource structure	p. 67
The key decision-making areas of resource structuring	p. 68
Contract labor	p. 68
Trade-force composition	p. 71
Plant specialization	p. 74
Trade-force location	p. 74
Non-daywork maintenance cover	p. 75
Sizing the trade-force	p. 77
Locations of spares, tools and information	p. 78
Logistics	p. 79
A systematic procedure for determining a resource structure	p. 79
For a new plant	p. 79
For an existing resource structure	p. 81
Summary	p. 84
Maintenance administrative structure	p. 89
Introduction	p. 90
Modeling administrative structures	p. 90
Traditional views on administrative management and some guidelines	p. 91
Characteristics of maintenance administrative structures	p. 97
The maintenance-engineering interface	p. 97
The maintenance-production interface	p. 99
Responsibility for spare parts management	p. 103
Vertical polarization	p. 103
The relationship between the professional engineer and the maintenance supervisor	p. 104
Major overhaul administration	p. 104
Summary	p. 106
The design or modification of the administrative structure	p. 107
Human factors in maintenance management	p. 111
Introduction	p. 112
What are 'human factors' in organizations?	p. 112
The human relations approach to management: a brief review	p. 113
Maintenance management behavioral characteristics	p. 114
Individual behavioral characteristics	p. 115
Group behavioral characteristics	p. 120
The effect of outsourcing alliances	p. 123
Auditing maintenance management human factors	p. 124
Trends in maintenance organization	p. 127
Introduction	p. 128
Traditional maintenance organizations	p. 128
Centralized resource structures	p. 129
Introduction of flexible working practices	p. 133
Plant manufacturing units	p. 136
Slimming the structure ('downsizing')	p. 139
The movement toward self-empowered plant-oriented teams	p. 142
Contracting, outsourcing and alliances	p. 145
Summary	p. 147
Maintenance organization case studies	p. 151
Case study 1: Moving with the times	p. 153
Introduction	p. 154
Background	p. 154
Audit of the CMG	p. 156
Setting up the alliance	p. 162
Observations	p. 164
Case studies 2 and 3: Cautionary tales of organizational change	p. 169
Introduction	p. 170
Case study 2: A bottling plant	p. 170
Background	p. 170
The plant maintenance strategy and organization	p. 171
Organizational change: the way forward	p. 173
Short-term actions	p. 174
Case study 3: An aluminum rolling mill	p. 175
Background	p. 175
Plant-operating characteristics and objectives	p. 177
Life plans and preventive schedules	p. 177
An overview of the organization	p. 178
Maintenance systems	p. 181
Observations and recommendations	p. 182
Case study 4: Reorganization of a colliery	p. 185
Introduction	p. 186
Maintenance consultancy at COALCOM - 1994	p. 186
Background to COALCOM	p. 186
Equipment and operating characteristics	p. 187
Production and maintenance objectives	p. 189
Life plans and preventive schedule	p. 189
Maintenance organization	p. 191
Maintenance systems	p. 196
Recommendations	p. 196
Progress visit and consultancy - 1997	p. 201
Introduction	p. 201
Organization	p. 201
Life plans and preventive schedule	p. 204
Recommendations - 1997	p. 204
Case study 5: The do's and don'ts of maintenance teams	p. 209
Introduction	p. 210
Characteristics of teams at Fertec B	p. 210
Characteristics of teams at Cario	p. 213
Improving team operation at Fertec B	p. 214
General comments on maintenance teams	p. 215
Case study 6: Maintenance audit of an agricultural chemical plant	p. 219
Introduction	p. 220
An overview of Fertec A	p. 220
Objectives	p. 222
Comments on objectives	p. 222
Maintenance strategy	p. 224
Plant-operating characteristics	p. 224
Ammonia plant maintenance strategy	p. 224
Maintenance organization	p. 232
Introduction	p. 232
The maintenance resource structure	p. 232
The maintenance administrative structure	p. 236
Total productive maintenance	p. 245
Total productive maintenance: its uses and limitations	p. 247
Introduction	p. 248
What is TPM?	p. 248
An early case study	p. 249
Fundamentals of TPM	p. 253
European applications by non-Japanese companies	p. 256
Summary	p. 261
Exercises	p. 267
Course exercises	p. 269
Exercise E14.1: The changing role of the maintenance supervisor	p. 269
Background	p. 269
Part A: The supervisor's role in a traditional organization	p. 270
Part B: The role of the supervisor after a 'downsizing' exercise	p. 270
Part C: Introduction of self-empowered work teams	p. 272
Exercise E14.2: Maintenance reorganization in a food processing plant	p. 274
Background	p. 274
Company organization and maintenance strategy	p. 276
The problem	p. 280
Index	p. 289
Table of Contents provided by Ingram. All Rights Reserved.

Managing Maintenance Resources

At a Glance

Paperback

Industry Reviews

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