RCM--Gateway to World Class Maintenance

By: Smith

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Hardcover | 4 November 2003 | Edition Number 2

At a Glance

Hardcover
362 Pages

Edition Type
Revised

Dimensions(cm)
22.86 x 15.24 x 2.06

Hardcover

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Reliability-Centered Maintenance provides valuable insights into current preventive maintenance practices and issues, while explaining how a transition from the current "preserve equipment" to "preserve function" mindset is the key ingredient in a maintenance optimization strategy. This book defines the four principal features of RCM and describes the nine essential steps to achieving a successful RCM program.

There is an easy to follow example illustrating the Classical RCM systems analysis process using the water treatment system for a swimming pool. As well as the use of software in the system analysis process, making a specific recommendation on a software product to use. Additionally, this new edition possesses an appendix devoted to discussing an economic model that has been used successfully to decide the most cost effective use of maintenance.

Top Level managers, engineers, and especially technicians who rely on PM programs in their plant operations can't afford to miss this inclusive guide to Reliability-Centered Maintenance.

*Includes detailed instructions for implementing and sustaining an RCM program for extremely cost effective manufacturing
*Presents seven real-world cross-industry RCM sucess case studies that have profited from this plan
*Provides essential information on how RCM focuses your maintenance organization to become a recognized "center for profit"
*Offers over 35 accumulated years of the authors' experiences in Lessons Learned for the proper use of RCM (and pitfalls to avoid)

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You Can Find This Book In

Non-Fiction Industry & Industrial Studies Industrial Relations, Health & Safety Health & Safety Issues Engineering & Technology Technology in General Engineering in General Business & Management Management & Management Techniques Quality Assurance QA & Total Quality Management TQM Mechanical Engineering & Materials Production & Industrial Engineering

Reliability Engineering Industrial Chemistry & Manufacturing Technologies Management of Specific Areas Production of Quality Control Management

Foreword	p. xiii
Preface	p. xix
Acknowledgments	p. xxi
World Class Maintenance (WCM)--Opportunity and Challenge	p. 1
Some Historical Aspects	p. 1
Some Common Maintenance Problems	p. 3
Proliferation of "Solutions"	p. 8
The Acronym Parade	p. 8
Benchmarking and Best Practices--Help or Hindrance?	p. 9
Maintenance Optimization--An Emerging Vision	p. 11
The Motivating Factor	p. 11
The Traditional Maintenance Mindset	p. 12
Rethinking Maintenance Strategy	p. 13
Focusing Resources--The 80/20 Rule	p. 14
World Class Maintenance (WCM)--Our Approach	p. 16
Preventive Maintenance--Definition and Structure	p. 19
What is Preventive Maintenance?	p. 19
Why Do Preventive Maintenance?	p. 21
Preventive Maintenance Task Categories	p. 22
Time-Directed (TD)	p. 23
Condition-Directed (CD)	p. 24
Failure-Finding (FF)	p. 25
CD Versus FF--A Distinction	p. 27
Run-To-Failure (RTF)	p. 28
Preventive Maintenance Program Development	p. 28
Current PM Development Practices and Myths	p. 30
PM Program Elements	p. 33
The "R" in RCM--Pertinent Reliability Theory and Application	p. 39
Introduction	p. 39
Reliability and Probabilistic Concepts	p. 40
Reliability in Practice	p. 43
Some Key Elements of Reliability Theory	p. 46
Failure Mode and Effects Analysis (FMEA)	p. 49
Availability and Preventive Maintenance	p. 54
RCM--A Proven Approach	p. 57
Some Historical Background	p. 57
The Bathtub Curve Fallacy	p. 58
The Birth of RCM	p. 61
What is RCM?	p. 63
Feature 1	p. 64
Feature 2	p. 65
Feature 3	p. 65
Feature 4	p. 66
The Four Features--A Summary	p. 66
Some Cost-Benefit Considerations	p. 67
RCM Methodology--The Systems Analysis Process	p. 71
Some Preliminary Remarks	p. 72
Step 1--System Selection and Information Collection	p. 74
Level of Assembly	p. 75
System Selection	p. 76
Information Collection	p. 79
Step 2--System Boundary Definition	p. 82
Step 3--System Description and Functional Block Diagram	p. 86
Step 3-1--System Description	p. 88
Step 3-2--Functional Block Diagram	p. 90
Step 3-3--IN/OUT Interfaces	p. 90
Step 3-4--System Work Breakdown Structure (SWBS)	p. 92
Step 3-5--Equipment History	p. 95
Step 4--System Functions and Functional Failures	p. 96
Step 5--Failure Mode and Effects Analysis	p. 98
Functional Failure-Equipment Matrix	p. 98
The FMEA	p. 100
Redundancy--General Rule	p. 106
Redundancy--Alarm and Protection Logic	p. 107
Step 6--Logic (Decision) Tree Analysis (LTA)	p. 107
Step 7--Task Selection	p. 112
Step 7-1--The Task Selection Process	p. 112
Step 7-2--Sanity Check	p. 117
Step 7-3--Task Comparison	p. 120
Task Interval and Age Exploration	p. 124
Items of Interest (IOI)	p. 127
Illustrating RCM--A Simple Example (Swimming Pool Maintenance)	p. 133
Step 1--System Selection and Information Collection	p. 134
System Selection	p. 134
Information Collection	p. 134
Step 2--System Boundary Definition	p. 135
Step 3--System Description and Functional Block Diagram	p. 139
Step 3-1--System Description	p. 139
Step 3-2--Functional Block Diagram	p. 142
Step 3-3--IN/OUT Interfaces	p. 142
Step 3-4--System Work Breakdown Structure (SWBS)	p. 145
Step 3-5--Equipment History	p. 146
Step 4--System Functions and Functional Failures	p. 147
Step 5--Failure Mode and Effects Analysis	p. 147
Step 6--Logic (Decision) Tree Analysis	p. 155
Step 7--Task Selection	p. 155
Step 7-1--Task Selection Process	p. 155
Step 7-2--Sanity Check	p. 155
Step 7-3--Task Comparison	p. 165
Alternative Analysis Methods	p. 171
Reducing Analysis Cost	p. 171
Abbreviated Classical RCM Process	p. 175
Step 1--System Selection and Information Collection	p. 175
Step 2--System Boundary Definition	p. 175
Step 3--System Description and Functional Block Diagram	p. 175
Step 4--Functions and Functional Failures	p. 176
Step 5--Failure Mode and Effects Analysis	p. 176
Step 6--Logic (Decision) Tree Analysis (LTA)	p. 177
Step 7--Task Selection	p. 177
Items of Interest (IOI)	p. 177
Experience-Centered Maintenance (ECM) Process	p. 177
Part A	p. 178
Part B	p. 180
Part C	p. 181
Implementation--Carrying RCM to the Floor	p. 183
Historical Problems and Hurdles	p. 184
Equipment-To-Function Hurdle	p. 185
Organizational Hurdle	p. 185
Run-To-Failure Hurdle	p. 185
CD and FF Hurdle	p. 186
Sacred Cows Hurdle	p. 186
Labor Reduction Hurdle	p. 187
PM Task Procedures Hurdle	p. 187
Labor and Material Adjustment Hurdle	p. 188
Gearing for Success	p. 188
Plan	p. 189
Do	p. 192
Check	p. 192
Act	p. 193
Interfacing with the CMMS	p. 193
Requirements for CMMS Integrated Support of RCM Activities	p. 194
Developing Effective and Useful Task Procedures	p. 197
RCM Rollup	p. 197
Procedural Development	p. 198
RCM Lessons Learned	p. 203
Organizational Factors	p. 204
The Structure Factor	p. 204
The Decision Factor	p. 205
The Financial Factor	p. 206
The Buy-In Factor	p. 209
RCM Teams	p. 210
Resource Allocation	p. 210
Team Makeup	p. 211
Personnel Selection	p. 212
Facilitator Role	p. 212
Scheduling Considerations	p. 213
Training	p. 214
System Selection	p. 215
Using IOIs (Items of Interest)	p. 217
O&M Peer Acceptance	p. 217
Program Management Considerations	p. 218
Feedback to Management	p. 218
Using Quantitative Reliability Data	p. 219
Information Traceability and Coding	p. 220
Key Factors in Success--and Failure	p. 221
The Living RCM Program	p. 223
Definition and Need	p. 223
The Four Factors of The Living RCM Program	p. 225
Adjustments to the Baseline RCM Analysis Results	p. 225
Plant Modifications	p. 226
New Information	p. 226
Program Measurement	p. 226
Reviewing The Living RCM Program	p. 228
Living RCM Program Process	p. 228
Software Support	p. 231
RCM Software--A Historical Journey	p. 231
An Observation	p. 232
Reducing RCM Analysis Effort and Cost	p. 233
Useful Attributes and Capabilities	p. 235
RCM Software--Our Pick	p. 237
Industrial Experience with Classical RCM	p. 239
Selected Component PM Task Comparisons	p. 239
Selected Case History Studies	p. 243
Three Mile Island--Unit 1 Nuclear Power Plant	p. 244
MidAmerican Energy--Power Plant Coal Processing	p. 255
Tennessee Valley Authority (TVA)--Cumberland Plant FGD	p. 265
Georgia-Pacific Corporation--Leaf River Pulp Operations	p. 274
Boeing Commercial Airplane--Frederickson Wing Responsibility Center	p. 281
Arnold Engineering Development Center (AEDC)--Von Karman Gas Dynamics Facility	p. 290
NASA--Ames Research Center/12 ft Pressure Tunnel (PWT)	p. 300
List of Acronyms	p. 309
The Mathematics of Basic Reliability Theory	p. 311
The Economic Value of Preventive Maintenance	p. 317
References	p. 331
Index	p. 335
About the Authors	p. 337
Table of Contents provided by Ingram. All Rights Reserved.

RCM--Gateway to World Class Maintenance

At a Glance

Hardcover

Shipping

How to return your order

Defective items

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