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RCM--Gateway to World Class Maintenance - Smith

RCM--Gateway to World Class Maintenance

By: Smith

Hardcover Published: 5th December 2003
ISBN: 9780750674614
Number Of Pages: 337

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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)

Forewordp. xiii
Prefacep. xix
Acknowledgmentsp. xxi
World Class Maintenance (WCM)--Opportunity and Challengep. 1
Some Historical Aspectsp. 1
Some Common Maintenance Problemsp. 3
Proliferation of "Solutions"p. 8
The Acronym Paradep. 8
Benchmarking and Best Practices--Help or Hindrance?p. 9
Maintenance Optimization--An Emerging Visionp. 11
The Motivating Factorp. 11
The Traditional Maintenance Mindsetp. 12
Rethinking Maintenance Strategyp. 13
Focusing Resources--The 80/20 Rulep. 14
World Class Maintenance (WCM)--Our Approachp. 16
Preventive Maintenance--Definition and Structurep. 19
What is Preventive Maintenance?p. 19
Why Do Preventive Maintenance?p. 21
Preventive Maintenance Task Categoriesp. 22
Time-Directed (TD)p. 23
Condition-Directed (CD)p. 24
Failure-Finding (FF)p. 25
CD Versus FF--A Distinctionp. 27
Run-To-Failure (RTF)p. 28
Preventive Maintenance Program Developmentp. 28
Current PM Development Practices and Mythsp. 30
PM Program Elementsp. 33
The "R" in RCM--Pertinent Reliability Theory and Applicationp. 39
Introductionp. 39
Reliability and Probabilistic Conceptsp. 40
Reliability in Practicep. 43
Some Key Elements of Reliability Theoryp. 46
Failure Mode and Effects Analysis (FMEA)p. 49
Availability and Preventive Maintenancep. 54
RCM--A Proven Approachp. 57
Some Historical Backgroundp. 57
The Bathtub Curve Fallacyp. 58
The Birth of RCMp. 61
What is RCM?p. 63
Feature 1p. 64
Feature 2p. 65
Feature 3p. 65
Feature 4p. 66
The Four Features--A Summaryp. 66
Some Cost-Benefit Considerationsp. 67
RCM Methodology--The Systems Analysis Processp. 71
Some Preliminary Remarksp. 72
Step 1--System Selection and Information Collectionp. 74
Level of Assemblyp. 75
System Selectionp. 76
Information Collectionp. 79
Step 2--System Boundary Definitionp. 82
Step 3--System Description and Functional Block Diagramp. 86
Step 3-1--System Descriptionp. 88
Step 3-2--Functional Block Diagramp. 90
Step 3-3--IN/OUT Interfacesp. 90
Step 3-4--System Work Breakdown Structure (SWBS)p. 92
Step 3-5--Equipment Historyp. 95
Step 4--System Functions and Functional Failuresp. 96
Step 5--Failure Mode and Effects Analysisp. 98
Functional Failure-Equipment Matrixp. 98
The FMEAp. 100
Redundancy--General Rulep. 106
Redundancy--Alarm and Protection Logicp. 107
Step 6--Logic (Decision) Tree Analysis (LTA)p. 107
Step 7--Task Selectionp. 112
Step 7-1--The Task Selection Processp. 112
Step 7-2--Sanity Checkp. 117
Step 7-3--Task Comparisonp. 120
Task Interval and Age Explorationp. 124
Items of Interest (IOI)p. 127
Illustrating RCM--A Simple Example (Swimming Pool Maintenance)p. 133
Step 1--System Selection and Information Collectionp. 134
System Selectionp. 134
Information Collectionp. 134
Step 2--System Boundary Definitionp. 135
Step 3--System Description and Functional Block Diagramp. 139
Step 3-1--System Descriptionp. 139
Step 3-2--Functional Block Diagramp. 142
Step 3-3--IN/OUT Interfacesp. 142
Step 3-4--System Work Breakdown Structure (SWBS)p. 145
Step 3-5--Equipment Historyp. 146
Step 4--System Functions and Functional Failuresp. 147
Step 5--Failure Mode and Effects Analysisp. 147
Step 6--Logic (Decision) Tree Analysisp. 155
Step 7--Task Selectionp. 155
Step 7-1--Task Selection Processp. 155
Step 7-2--Sanity Checkp. 155
Step 7-3--Task Comparisonp. 165
Alternative Analysis Methodsp. 171
Reducing Analysis Costp. 171
Abbreviated Classical RCM Processp. 175
Step 1--System Selection and Information Collectionp. 175
Step 2--System Boundary Definitionp. 175
Step 3--System Description and Functional Block Diagramp. 175
Step 4--Functions and Functional Failuresp. 176
Step 5--Failure Mode and Effects Analysisp. 176
Step 6--Logic (Decision) Tree Analysis (LTA)p. 177
Step 7--Task Selectionp. 177
Items of Interest (IOI)p. 177
Experience-Centered Maintenance (ECM) Processp. 177
Part Ap. 178
Part Bp. 180
Part Cp. 181
Implementation--Carrying RCM to the Floorp. 183
Historical Problems and Hurdlesp. 184
Equipment-To-Function Hurdlep. 185
Organizational Hurdlep. 185
Run-To-Failure Hurdlep. 185
CD and FF Hurdlep. 186
Sacred Cows Hurdlep. 186
Labor Reduction Hurdlep. 187
PM Task Procedures Hurdlep. 187
Labor and Material Adjustment Hurdlep. 188
Gearing for Successp. 188
Planp. 189
Dop. 192
Checkp. 192
Actp. 193
Interfacing with the CMMSp. 193
Requirements for CMMS Integrated Support of RCM Activitiesp. 194
Developing Effective and Useful Task Proceduresp. 197
RCM Rollupp. 197
Procedural Developmentp. 198
RCM Lessons Learnedp. 203
Organizational Factorsp. 204
The Structure Factorp. 204
The Decision Factorp. 205
The Financial Factorp. 206
The Buy-In Factorp. 209
RCM Teamsp. 210
Resource Allocationp. 210
Team Makeupp. 211
Personnel Selectionp. 212
Facilitator Rolep. 212
Scheduling Considerationsp. 213
Trainingp. 214
System Selectionp. 215
Using IOIs (Items of Interest)p. 217
O&M Peer Acceptancep. 217
Program Management Considerationsp. 218
Feedback to Managementp. 218
Using Quantitative Reliability Datap. 219
Information Traceability and Codingp. 220
Key Factors in Success--and Failurep. 221
The Living RCM Programp. 223
Definition and Needp. 223
The Four Factors of The Living RCM Programp. 225
Adjustments to the Baseline RCM Analysis Resultsp. 225
Plant Modificationsp. 226
New Informationp. 226
Program Measurementp. 226
Reviewing The Living RCM Programp. 228
Living RCM Program Processp. 228
Software Supportp. 231
RCM Software--A Historical Journeyp. 231
An Observationp. 232
Reducing RCM Analysis Effort and Costp. 233
Useful Attributes and Capabilitiesp. 235
RCM Software--Our Pickp. 237
Industrial Experience with Classical RCMp. 239
Selected Component PM Task Comparisonsp. 239
Selected Case History Studiesp. 243
Three Mile Island--Unit 1 Nuclear Power Plantp. 244
MidAmerican Energy--Power Plant Coal Processingp. 255
Tennessee Valley Authority (TVA)--Cumberland Plant FGDp. 265
Georgia-Pacific Corporation--Leaf River Pulp Operationsp. 274
Boeing Commercial Airplane--Frederickson Wing Responsibility Centerp. 281
Arnold Engineering Development Center (AEDC)--Von Karman Gas Dynamics Facilityp. 290
NASA--Ames Research Center/12 ft Pressure Tunnel (PWT)p. 300
List of Acronymsp. 309
The Mathematics of Basic Reliability Theoryp. 311
The Economic Value of Preventive Maintenancep. 317
Referencesp. 331
Indexp. 335
About the Authorsp. 337
Table of Contents provided by Ingram. All Rights Reserved.

ISBN: 9780750674614
ISBN-10: 075067461X
Audience: Professional
Format: Hardcover
Language: English
Number Of Pages: 337
Published: 5th December 2003
Country of Publication: GB
Dimensions (cm): 23.42 x 15.95  x 2.57
Weight (kg): 0.73
Edition Number: 2
Edition Type: Revised

Earn 266 Qantas Points
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