The Maintenance Management Framework

The Maintenance Management Framework

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English

Description


The Maintenance Management Framework describes and reviews the concept, process and framework of modern maintenance management of complex systems; concentrating specifically on modern modelling tools (deterministic and empirical) for maintenance planning and scheduling. It presents a new perspective of maintenance management by:




  • focusing on the course of maintenance actions;



  • presenting a structure that ensures proper support for current maintenance managers;



  • clarifying the functionality that is required from information technology when applied to maintenance and the functions of modern maintenance engineering; and



  • creating a set of practical models for maintenance management planning and scheduling.


The discussion of all of these issues is supported through the use of case studies.



The Maintenance Management Framework will be beneficial for engineers and professionals involved in: maintenance management, maintenance engineering, operations management, quality, etc. It will also be of interest to graduate students and researchers in this field.

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Informations

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Published 10 June 2007
Reads 5
EAN13 9781846288210
License: All rights reserved
Language English
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Contents
PART 1. Maintenance Management Definition and Characterization
1 On the Definition of Maintenance Management ........................................3  1.1 A Definition of Maintenance Management............................................3  1.2 Effectiveness and Efficiency of Maintenance Management ..................4  1.3 Maintenance Objectives, Strategy and Responsibilities ........................5  1.3.1 Setting Maintenance Objectives .................................................5  1.3.2 Formulating Strategy ..................................................................7  1.3.3 Establishing Responsibilities ......................................................7  1.4 Strategy Implementation at the Three Levels of Activity: Strategic,  Tactical and Operational........................................................................9  1.5 References……....................................................................................10 2 Maintenance Management Characterization: Process, Framework  and Supporting Pillars ...............................................................................11 2.1 A Reason for MM Characterization.....................................................11 2.2 The Maintenance Management Process...............................................14 2.2.1 The Course of Action ...............................................................14 2.2.2 Maintenance Planning. .............................................................14 2.2.3 Maintenance Scheduling...........................................................17 2.2.4 Managing Maintenance Actions Execution ..............................18 2.2.5 Maintenance Assessment..........................................................18 2.2.6 Ensuring Continuous Improvement ..........................................20 2.2.7 Considering Equipment Re-design ...........................................21 2.3 Maintenance Management Framework................................................21 2.3.1 A Review on Maintenance Framework ....................................22 2.3.2 Defining the Structure to Support Maintenance Management..24 2.4 Functions of the MM Supporting Pillars..............................................27 2.4.1 Functions of the IT Pillar..........................................................27 2.4.2 Functions of the ME Pillar........................................................30 2.4.3 Functions of the Organizational Pillar ......................................36 2.5 References............................................................................................38
xiv Contents
PART 2. Basic Concepts for Complex Systems Maintenance
3 4 5 6
The Failure Concept ...................................................................................43 3.1 Failure Event and Related Terms.........................................................433.2 Fault State and Related Terms .............................................................44 3.3 The Maintenance Time ........................................................................45 3.4 References............................................................................................47
Failure Models ............................................................................................49 4.1 The Importance of Failure Data ...........................................................49 4.2 Basic Functions to Model Failures ......................................................50 4.3 Empiricalvs.....................53Theoretical Failure Distribution Functions 4.4 Weibull Distribution Function and Weibull Analysis..........................54 4.5 Weibull Analysis .................................................................................57 4.6 References............................................................................................67
The Maintenance Concept .........................................................................69 5.1 Maintenance Types ..............................................................................69  5.1.1 Maintenance Type Classification .............................................69  5.1.2 Preventive Maintenance ...........................................................70  5.1.3 Corrective Maintenance............................................................71 5.2 Maintenance Activities ........................................................................71 5.3 The Indenture Level.............................................................................72 5.4 The Maintenance Level .......................................................................73 5.5 The Maintenance Line or Echelon .......................................................74 5.6 The Maintenance Policy ......................................................................75 5.7 References............................................................................................76
Basic Maintenance Models.........................................................................77 6.1 Introduction to Maintenance Policy Modelling ...................................77 6.2 Total Replacement Models ..................................................................78  6.2.1 Constant Interval Replacement (CIR). .....................................79  6.2.2 Age Based Replacement (ABR). ..............................................81 6.3 Partial Replacement Models ................................................................82  6.3.1 PPR with Minimal Repairs .......................................................83  6.3.2 PPR with Normal Repairs (NR) ...............................................84 6.4 Replacement Models with Imperfect Maintenance (IPM) ...................85 6.5 Shock Based Replacement Models ......................................................87 6.6 Inspection Models................................................................................87 6.7 References............................................................................................89
Contents xv
PART 3. Developing the Maintenance Management Framework
7 A Review of Key Decision Areas in Maintenance Management  Modelling….................................................................................................93  7.1 Introduction..........................................................................................93  7.2 A Generic Model for Maintenance Management.................................93  7.3 Definition of Maintenance Objectives and Strategy ............................95  7.4 Asset Priority and Maintenance Strategy Definition ...........................95  7.5 Immediate Intervention on High Impact Weak Points.........................96  7.6 Design of the Preventive Maintenance Plans and Resources...............97  7.7 Preventive Plan, Schedule and Resources Optimization......................97  7.8 Maintenance Execution Assessment and Control ................................98  7.9 Asset Life Cycle Analysis and Replacement Optimization .................98  7.10 Continuous Improvement and New Techniques Utilization ................98  7.11 References............................................................................................99 8 Definition of Maintenance Objectives and Strategy .............................. 101  8.1 Introduction........................................................................................ 101  8.2 BSC and Maintenance ....................................................................... 101  8.3 Proper Selection of Maintenance KPIs .............................................. 103  8.4 From Key Performance Indicators to Functional Indicators .............. 104  8.5 References.......................................................................................... 106 9 Criticality Analysis for Asset Priority Setting ........................................ 107  9.1 Introduction........................................................................................ 107  9.2 Criticality Analysis Using Qualitative Techniques............................ 107  9.2.1 Case Study: Manufacturing Plant Criticality Flowchart. ........ 108  9.3 Criticality Analysis Using Risk Assessment Techniques .................. 111  9.3.1 Case Study: A Petrochemical Plant ........................................ 112  9.4 Criticality Analysis Using AHP......................................................... 116  9.4.1 Case Study: AHP Applied to the Petrochemical Plant. .......... 117  9.5 Maintenance Strategy Definition ....................................................... 124  9.6 References.......................................................................................... 126 10 Root Cause Failure Analysis (RCFA) for High Impact Weak Points .. 127  10.1 RCFA When and Why ....................................................................... 127  10.2 RCFA Techniques in Literature......................................................... 128  10.3 Failure Cause Characterization .......................................................... 129  10.4 Failure Root Cause Analysis Method and Process ............................ 129  10.5 Case Study ......................................................................................... 131  10.6 References.......................................................................................... 132 11 A Method to Design the Maintenance Plan ............................................ 133  11.1 An Introduction to RCM History ....................................................... 133
xvi Contents
11.2 RCM Concept .................................................................................... 134 11.3 RCM Implementation ........................................................................ 135  11.3.1 The Process and the Review Team ......................................... 135  11.3.2 System Selection and Definition of the Operational Context. 138 11.4 Failure Mode and Effect Analysis (FMEA)....................................... 138  11.4.1 Introduction to the Methodology ............................................ 138  11.4.2 Describing Functions.............................................................. 139  11.4.3 Defining Functional Failures .................................................. 140  11.4.4 Definition of the Failure Modes ............................................. 142  11.4.5 The Description of the Failure Modes Effects........................ 143 11.5 RCM and the Hidden Failure Modes ................................................. 148  11.5.1 RCM and the Hidden Failures ................................................ 148  11.5.2 Hidden Failures and Their Maintenance................................. 149  11.5.3 Maintenance Actions to Prevent Multiple Failures Caused by Hidden Failure Modes............................................................. 150 11.6 Selection of Maintenance Activities Within RCM ............................ 150  11.6.1 The Determination of the Consequences of a Failure Mode .. 150  11.6.2 Preventive Activities............................................................... 152  11.6.3 Corrective Activities............................................................... 154 11.7 Concluding Remarks.......................................................................... 154 11.8 References.......................................................................................... 155 12 Models to Deal with Maintenance Capacity Planning ........................... 157 12.1 Models for Maintenance Resources Management ............................. 157 12.2 Maintenance Staff Planning and Scheduling. .................................... 157  12.2.1 Queuing Theory Models for Birth-and-death Processes......... 159  12.2.2 Monte Carlo Simulation Models. ........................................... 167 12.3 Maintenance Materials Requirements Planning................................. 172  12.3.1 Statistical Inventory Models ................................................... 174  12.3.2 Selective Control Procedures along with Heuristics............... 177  12.3.3 Using the Material Requirements Planning/Manufacturing Requirements Planning (MRP/MRPII) Technique ................. 178 12.4 A Model for Maintenance Contracts.................................................. 180  12.4.1 Proposed Maintenance Contract Structure ............................. 180 12.5 References.......................................................................................... 183 13 Models to Deal with Maintenance Activities Planning .......................... 185 13.1 Markov Processes Models ................................................................. 185 13.2 Maintenance Optimization Models for Markovian Processes ........... 187  13.2.1 Modelling Deterioration ......................................................... 188  13.2.2 Modelling Corrective Maintenance ........................................ 191  13.2.3 Modelling Predetermined Maintenance.................................. 195  13.2.4 Modelling Predetermined Age Based Maintenance ............... 198  13.2.5 Modelling Predetermined Age and Inspection Based Maintenance ............................................................................ 202 13.3 Semi-Markov Process Models for Planning ...................................... 209  13.3.1 Formulation of the SMDP Model ........................................... 209
Contents xvii
 13.3.2 Modelling Corrective Maintenance ........................................ 213  13.3.3 Modelling Imperfect Corrective Maintenance........................ 214  13.3.4 Modelling Preventive Maintenance ........................................ 216  13.3.5 Case Study .............................................................................. 219  13.4 References.......................................................................................... 223 14 Models to Deal with Maintenance Scheduling Issues ............................ 225  14.1 Introduction to the Maintenance Scheduling Process ........................ 225  14.2 CPM and PERT Methods .................................................................. 227  14.2.1 History of Network Analysis .................................................. 227  14.2.2 The Critical Path Method (CPM) ........................................... 228  14.2.3 The Programme Evaluation Review Technique (PERT) ........ 230  14.2.4 A Maintenance Project Case Study with CPM/PERT ............ 233  14.3 Maintenance Scheduling and Cost Analysis Methods ....................... 238  14.3.1 Problem Discusion and Case Study ........................................ 238  14.3.2 Speeding up the Project at the Minimum Cost Increase ......... 239  14.4 Using Monte Carlo Simulation Modelling for the PM Scheduling Problem .............................................................................................. 244  14.4.1 Introduction ............................................................................ 244  14.4.2 Case Study: Scheduling Maintenance of a Capacity Constrained Production System. ........................................... 245  14.4.3 Modelling the Production System .......................................... 246  14.4.4 Optimization of the PM Scheduling Policy ............................ 253  14.4.5 Simulation and Optimization Results ..................................... 257  14.4.6 Summary of Findings ............................................................. 261  14.5 References.......................................................................................... 261 15 Overall Maintenance Management Assessment..................................... 263  15.1 Introduction........................................................................................ 263  15.2 Time Variables Characterization ....................................................... 263  15.3 Definition of Common Time-related Measures ................................. 266  15.4 Measuring Item Operational Dependability....................................... 267  15.4.1 Operational Availability ......................................................... 267  15.4.2 Operational Reliability ........................................................... 267  15.4.3 Operational Maintainability.................................................... 267  15.5 Maintenance Management Effectiveness Assessment ....................... 268  15.6 Maintenance Management Efficiency Assessment............................ 270  15.7 References.......................................................................................... 271 16 Failures Impact on Life Cycle Cost Analysis.......................................... 273  16.1 Introduction........................................................................................ 273  16.2 Basic Elements of the LCCA ............................................................. 275  16.3 Cost Characterization in Different Phases of the Equipment Life Cycle ........................................................................................... 276  16.4 Reliability Impact on Life Cycle Cost ............................................... 278  16.5 Models to Assess Reliability Impact on LCCA ................................. 279  16.5.1 Constant Failure Rate Model .................................................. 279
xviii Contents
 16.5.2 Deterministic Failure Rate Model .......................................... 281  16.5.3 Weibull Distribution Failure Rate Model ............................... 282  16.5.4 Summary of Key Aspects and Limitations per Model............ 285 16.6 Case Study ......................................................................................... 286  16.6.1 Case Study.......................... 286Constant Failure Rate Model  16.6.2 Case Study287Deterministic Failure Rate Model...................  16.6.3 Case Study288Weibull Distribution Failure Rate Model ........  16.6.4 Case Study289Discussion of Results....................................... 16.7 Concluding Remarks.......................................................................... 289 16.8 References.......................................................................................... 291 17 Maintenance Continuous Improvement Through Organizational Efficiency… ............................................................................................... 293 17.1 Introduction........................................................................................ 293 17.2 Creating People Ownership of the Manufacturing Process ............... 294 17.3 Introducing Autonomous Maintenance (AM).................................... 295  17.3.1 Defining the Process............................................................... 295  17.3.2 Defining the New Functions................................................... 297 17.4 Pursuing Overall Organizational Effectiveness. ................................ 298 17.5 Maintenance Planning and Maintenance Quality .............................. 300 17.6 Early Equipment Management for Maintenance Prevention ............. 302 17.7 Improving Maintenance Through Education and Training................ 302 17.8 References.......................................................................................... 303 18 The E-maintenance Revolution ............................................................... 305 18.1 Introduction........................................................................................ 305 18.2 Factors for the Emergence of E-maintenance .................................... 306 18.3 The E-maintenance Capabilities ........................................................ 308  18.3.1 E-maintenance, the New Areas of Advantage ........................ 308  18.3.2 Potential Improvements of Maintenance Type and Strategies Provided by E-maintenance .................................................... 308  18.3.3 Potential Improvements of Maintenance Support and Tools Provided by E-maintenance .................................................... 310  18.3.4 Potential Improvements of Maintenance Activities Provided by E-maintenance......................................................................... 312 18.4 Challenges for E-maintenance ........................................................... 312  18.4.1 E-maintenance Requirements ................................................. 312  18.4.2 Needs for E-maintenance Related to Maintenance Type and Strategies................................................................................. 313  18.4.3 Needs for E-maintenance Related to Maintenance Support and Tools................................................................................. 314  18.4.4 Needs for E-maintenance Related to Maintenance Activities 315 18.5 State of the art in E-maintenance ....................................................... 315  18.5.1 Introduction ............................................................................ 315  18.5.2 Standards Development in E-Maintenance............................. 315  18.5.3 E-Maintenance Processes Formalization ................................ 321
Contents xix
 18.6 Concluding Remarks.......................................................................... 322  18.7 E-maintenance New Terminology ..................................................... 323  18.8 References.......................................................................................... 324 Index……………………………………………………………………...…...329
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