Transcription
Mohamed Ben-Daya Salih O. DuffuaaAbdul Raouf Jezdimir Knezevic Daoud Ait-KadiEditorsHandbook ofMaintenance Managementand EngineeringSpringer
ContentsList of ContributorsxxvPart I - Maintenance Organization1 Maintenance OrganizationAhmed E. Haroun and Salih O. Duffuaa1.1 Introduction1.2 Maintenance Organization Objectives and Responsibility1.3 Determinants of a Maintenance Organization1.3.1 Maintenance Capacity Planning1.3.2 Centralization vs Decentralization1.3.2 In-house vs Outsourcing1.4 Design of the Maintenance Organization1.4.1 Current Criteria for Organizational Change1.4.2 Criteria to Assess Organizational Effectiveness1.5 Basic Types of Organizational Models1.6 Material and Spare Parts Management1.7 Establishment of Authority and Reporting1.8 Quality of Leadership and Supervision1.9 Incentives1.10 Education and Training1.11 Management and Labor Relations1.12 SummaryReferences2 Maintenance Productivity and Performance MeasurementAdityct Parida and Uday Kumar2.1 Introduction2.2 Performance Measurement and Maintenance Productivity2.3 Maintenance Performance2.4 Measurement of Maintenance Productivity3356677889910131313141415151717192123
xiiContents2.4.1 Maintenance Performance Indicator (MPI)2.4.2 MPM Issues2.4.3 MPM System2.5 MPI Standards and MPIs as in Use in Different Industries2.5.1 Nuclear Industry2.5.2 Maintenance Indicators by EFNMS2.5.3 SMRP Metrics2.5.4 Oil and Gas Industry2.5.5 Railway Industry2.5.6 Process Industry2.5.7 Utility Industry2.5.8 Auto-industry Related MPIs for the CEO2.6 Concluding RemarksReferences2424273132333435363637383939Part II - Methods and Tools in Maintenance3 Failure StatisticsMohamed Ben-Daya3.1 Introduction3.2 Introduction to Probability3.2.1 Sample Spaces and Events3.2.2 Definition of Probability3.2.3 Probability Rules3.2.4 Conditional Probabilities3.2.5 Random Variables3.3 Probability Distributions3.4 Reliability and Failure Rate Functions3.4.1 Introduction3.4.2 Reliability Function3.4.3 Failure Rate Function3.4.4 Mean Time Between Failure (MTBF)3.5 Commonly Used Distributions3.5.1 The Binomial Distribution3.5.2 The Poisson Distribution3.5.3 The Normal Distribution3.5.4 The Lognormal Distribution3.5.5 The Exponential Distribution3.5.6 The Weibull Distribution3.6 Failure Statistics3.6.1 Types of Data3.6.2 Parameter EstimationReferences4 Failure Mode and Effect AnalysisMohamed Ben-Daya4.1 6061636364737575
Contents4.24.34.44.5FMEA DefinedFMEA ProcessFMEA ApplicationsRelated Tools4.5.1 Root Cause Analysis4.5.2 Pareto Chart4.5.3 Cause and Effect DiagramReferencesxiii7678838383878790Part III - Maintenance Control Systems5 Maintenance ControlSalih О. Duffuaa and Ahmed E. Haroun5.1 Introduction5.2 The Maintenance Control Function5.3 The Control Process5.4 Functional Structure of Maintenance Control5.5 Work Order System5.5.1 Basic Documentation for Work Order System5.5.2 Work Order System Flow5.6 Tools Necessary for Effective Maintenance Control System5.6.1 Work Control5.6.2 Cost Control5.6.3 Quality Control5.6.4 Plant Condition Control5.7 Effective Programs for Improving Maintenance Control5.7.1 Emergency Maintenance5.7.2 Reliability Improvement5.7.3 Total Productive Maintenance5.7.4 Computerized Maintenance Management and InformationTechnology5.8 SummaryReferences6 Guidelines for Budgeting and Costing Planned Maintenance ServicesMohamed Ali Mirghani6.1 Introduction6.2 An Overview of Budgeting and Costing Systems6.2.1 Budgeting Systems6.2.2 Costing Systems6.3 Proposed Budgetary System6.3.1 Planned Maintenance Operating Budget6.3.2 Financial Budget6.3.3 The Budget Cycle6.3.4 Top Management Support6.3.5 Budget Performance Reports6.4 Planned Maintenance Job 1111112112115115116116117118118119120120122123
xivContents6.4.1 Standard Cost Elements of a Planned Maintenance Job6.4.2 Actual Cost Elements of a Planned Maintenance Job6.4.3 Total Cost of a Planned Maintenance Job6.4.4 Planned Maintenance Job Cost Variances6.4.5 Significant Cost Variances6.5 Summary and ConclusionsReferences1231281291291301311327 Simulation Based Approaches for Maintenance Strategies Optimization. 133Fouad Riane, Olivier Roux, Olivier Bas He, and Pierre Dehombreux7.1 Introduction1337.2 Reliability Models Estimation1347.2.1 Regression and ML Methods1347.2.2 Uncertainty Affecting Reliability Model1367.3 Maintenance Performance1387.3.1 Availability Model1387.3.2 Costs Model1397.4 Simulation Based Maintenance Framework1417.4.1 Toward a Unified Framework1417.4.2 Maintenance Strategies1427.4.3 Uncertainty Affecting Maintenance Performances1467.5 A Case Study1487.6 Conclusion152References152Part IV - Maintenance Planning and Scheduling8 Maintenance Forecasting and Capacity PlanningHesham K. Alfares andSalih O. Duffuaa8.1 Introduction8.2 Forecasting Basics8.3 Qualitative Forecasting Techniques8.3.1 The Delphi Method8.4 Quantitative Forecasting Techniques8.4.1 Simple Moving Averages8.4.2 Weighted Moving Average8.4.3 Regression Analysis8.4.4 Exponential Smoothing8.4.5 Seasonal Forecasting8.4.6 Box-Jenkins Time Series Models8.5 Error Analysis8.6 Forecasting Maintenance Workload8.7 Maintenance Capacity Planning8.8 Deterministic Approaches for Capacity Planning8.8.1 Modified Transportation Tableau Method8.8.2 Mathematical Programming Methods8.9 Stochastic Techniques for Capacity 175176176179182
Contents8.9.1 Queuing Models8.9.2 Stochastic Simulation8.10 SummaryReferencesxv1821861881899 Integrated Spare Parts Management191Claver Diallo, Daoud Ait-Kadi, and Anis Chelbi9.1 Introduction1919.2 Spare Parts Identification and Classification1929.3 Determination of the Required Quantity of Spare Parts1939.3.1 Recommendations1939.3.2 Reliability and Availability Based Procedures1939.3.3 Forecasting Procedure1989.3.4 Simulation2009.4 Inventory Control Policies2019.4.1 Model with Known and Constant Demand and Lead-time (EOQModel)2029.4.2 Model with Constant Demand and Perishable Items2029.4.3 Model with Random Demand and Lead-time2039.5 Joint Maintenance and Provisioning Strategies2049.5.1 Joint Replacement and Ordering Policy for a Spare Unit (One UnitProvisioning)2059.5.2 Joint Replacement and Multiple Spare Parts Ordering Policy (BatchProvisioning)2079.6 Inventory and Maintenance Policies for Reconditioned Spare Parts2099.6.1 Age of Recovered Parts to be Used for Replacement Actions2099.6.2 Review of Inventory Control Policies with Random Returns2139.7 Collaborative Management of Spare Parts2139.7.1 Access to Documentation and Knowledge Bases2139.7.2 Lead-time Reduction2149.7.3 Virtually Centralized Spare Parts Stock (Inventory Pooling)2149.7.4 Joint Replenishment of Spare Parts2169.8 Conclusion218References21810 Turnaround MaintenanceSalih Duffuaa and Mohamed Ben-Daya10.1 Introduction10.2 Turnaround Initiation10.3 Work Scope10.4 Long Lead Time Resources10.5 Contractors10.6 ТАМ Planning10.7 ТАМ Organization10.8 Site Logistics10.9 ТАМ Budget10.10 Quality and Safety Plans223223225226227228228229230230231
xviContents10.10.1 Quality Plan10.10.2 Safety Plan10.11 ТАМ Communication Procedures10.12 ТАМ Execution10.13 ТАМ Closing and Final Report10.14 ConclusionReferences11 Maintenance Planning and SchedulingUmar M. Al-Turki11.1 Introduction11.2 Strategic Planning in Maintenance11.3 Medium Range Planning11.4 Short Range Planning11.5 Maintenance Scheduling11.5.1 Elements of Sound Scheduling11.5.2 Maintenance Job Priority System11.6 Scheduling Techniques11.6.1 Gantt Charts and Scheduling Theory11.6.2 Project Scheduling11.6.3 Critical Path Method11.6.4 Program Evaluation Review Techniques (PERT)11.7 Scheduling Using Computers11.8 SummaryReferences12 Models for Production and Maintenance Planning in StochasticManufacturing SystemsE.K. Boukas12.1 Introduction12.2 Problem Statement and Preliminary Results12.3 Dynamic Programming Approach12.4 Linear Programming Approach12.5 4280295296Part V - Maintenance Strategies13 Inspection Strategies for Randomly Failing SystemsAnis Chelbi and Daoud Ait-Kadi13.1 Introduction13.1.1 Notation13.2 Basic Inspection Model13.2.1 Problem Definition13.2.2 Working Assumptions and Mathematical Model13.3 Extensions of the Basic Model13.3.1 Inspection Models for Single Component Systems303303304305305306308308
Contents xvii13.4 Inspection Models for Multi-component Systems31813.4.1 Failure Tree Method Based Strategies31813.4.2 Cases of Cold and Hot Stand-by Systems with Known andPartially Known Lifetime Distributions31913.4.3 Case of Systems with Components Failure Dependency32013.5 Conditional Maintenance Models32113.5.1 Conditional Maintenance Models for Single Component Systems.32113.5.2 Conditional Maintenance Models for Multi-Component Systems.32913.6 Conclusion331References33214 System Health Monitoring and Prognostics - A Review of CurrentParadigmsand PracticesRanganath Kothamasu, Samuel H. Huang, William H. VerDuin14.1 Maintenance Strategies: Motivations for Health Monitoring14.2 Health Monitoring Paradigms14.3 Health Monitoring Tools and Techniques14.3.1 Reliability-based Maintenance14.3.2 Model-based Approach to FDI14.3.3 Signal-based FDI14.3.4 Statistical FDI/Maintenance14.4 Case Studies in System Monitoring and Control14.5 Organizations and Standards14.6 Summary and Research DirectionsReferences15 Applied Maintenance ModelsK. Ito and T. Nakagawa15.1 Introduction15.2 Missile Maintenance15.2.1 Expected Cost15.2.2 Optimal Inspection Policies15.2.3 Numerical Illustrations15.3 Phased Array Radar Maintenance15.3.1 Cyclic Maintenance15.3.2 Delayed Maintenance15.3.3 Numerical Illustrations15.4 Self-diagnosis for FADEC15.4.1 Double Module System15.4.2 Triple Module System15.4.3 N Module System15.4.4 Numerical Illustrations15.5 Co-generation System Maintenance15.5.1 Model and Assumptions15.5.2 Analysis15.5.3 Optimal Policy15.5.4 Numerical 386387388389390391392
xviii Contents16 Reliability Centered MaintenanceAtiq Waliullah Siddiqui and Mohamed Ben-Daya16.1 Introduction16.2 RCM Philosophy16.2.1 RCM Principles and Key Features16.2.2 RCM Goals and Benefits16.2.3 System, System Boundary, Interfaces and Interactions16.3 Failure and its Nature16.4 RCM Methodology16.4.1 Selecting Systems Selection and Collecting Information16.4.2 System Boundary Definition16.4.3 System Description and Functional Block Diagram16.4.4 System Functions and Functional Failure16.4.5 Failure Mode and Effective Analysis (FEMA)16.4.6 Logic or Decision Tree Analysis (LTA)16.4.7 Task Selection16.5 RCM Implementation16.5.1 Organizational Factors16.5.2 RCM Teams16.5.3 Scheduling Consideration and Training16.6 ConclusionReferences17 Total Productive MaintenanceP.S. Ahuja17.1 Introduction to TPM17.2 Evolution Towards TPM17.3 Need of TPM17.4 Basic Elements of TPM17.5 Roadmap for TPM Implementation17.6 An Ideal TPM Methodology17.6.1 Introduction Phase (Phase I)17.6.2 TPM Initiatives Implementation Phase (Phase II)17.6.3 Standardization Phase (Phase III)17.7 Barriers in TPM Implementation17.8 Success Factors for Effective TPM Implementation17.9 SummaryReferences18 Warranty and MaintenanceD.N. P. MurthyandN. Jack18.1 Introduction18.2 Maintenance Modelling18.2.1 Reliability18.2.2 Types of Maintenance18.2.3 Failure 51453456458458461461462462462462
Contents18.3 Warranties18.3.1 Base Warranties18.3.2 Classification of Base Warranties18.3.3 Warranty Servicing Cost Analysis18.3.4 Extended Warranties18.4 Link Between Warranty and Maintenance18.4.1 Taxonomy for Classification18.4.2 Warranty Servicing Involving Only CM18.4.3 Warranty Servicing Involving Both CM and PM18.5 Maintenance Logistics for Warranty Servicing18.5.1 Strategic Issues18.5.2 Tactical and Operational Issues18.6 Outsourcing of Maintenance for Warranty Servicing18.6.1 Agency Theory18.7 Conclusions and Topics for Future 047147247447447647619 Delay Time Modeling for Optimized Inspection Intervals ofProduction Plant479Wenbin Wang19.1 Introduction47919.2 The DT Concept and Modeling Characteristics48019.3 The DT Models for Complex Plant48319.3.1 The Down Time/Cost Model48319.3.2 Modeling E[Nf((i-\)T,iT)\and E[Ns(iT)] Under the Assumptionof Perfect Inspections19.3.3 Modeling E[Nf((i-\)T,iT)]484and E[Ns(iT)] Under the Assumptionof Imperfect Inspections48519.4 Delay Time Model Parameters Estimation48719.4.1 Introduction48719.4.2 Complex System - Parameter Estimation48819.5 A Case Example49319.6 Other Developments in DT Modeling and Future Research Directions .496References49720 Integrated E-maintenance and Intelligent Maintenance SystemsJayantha P. Liyanage, Jay Lee, Chris tos Emmanouilidis, andJun Ni20.1 Introduction20.2 Condition-based Maintenance Technology and the State ofDevelopment20.3 Integrated E-maintenance Solutions and Current Status20.4 Technical Framework for E-maintenance20.5 Watchdog Agent-based Intelligent Maintenance Systems20.5.1 R2M-PHM Platform20.5.2 System Architecture499499501503507511511512
xxContents20.5.3 Toolbox for Multi-sensor Performance Assessment andPrognostics20.5.4 Maintenance Decision Support System20.6 Technology Integration for Advanced E-maintenance20.6.1 Generic ICT Interface20.6.2 Generic Interface Requirements for Watchdog Agents20.6.3 Systems-user Interface Needs20.7 Some Industrial Applications20.7.1 E-maintenance Solutions for Complex Industrial Assets20.7.2 Watchdog Technology for Product Life-cycle Design andManagement20.7.3 Watchdog Technology to Trouble-shoot Bearing Degradation20.8 Challenges of E-maintenance Application Solutions20.9 536538539Part VI - Maintainability and System Effectiveness21 Maintainability and System EffectivenessJ. Knezevic21.1 Introduction21.2 The Concept of Maintainability21.2.1 Maintainability Impact on System Effectiveness21.2.2 Maintainability Impact on Safety21.2.3 Undesirable Maintainability Practices21.2.4 Desirable Maintainability Practices21.3 Maintainability Analysis21.3.1 Measures of Maintaniablity21.3.2 Maintenance Labour-hour Factors21.3.3 Maintenance Frequency Factors21.3.4 Maintenance Cost Factors21.3.5 Related Maintenance Factors21.4 Empirical Data and Maintainability Measures21.4.1 Possible Approaches to Analysis of Existing Data21.4.2 Parametric Approach to Maintainability Data21.4.3 Distribution Approach to Maintainability Data21.4.4 Distribution Approach21.5 Maintainability Engineering Predictions21.5.1 Introduction21.5.2 Concept of the Maintainability Block Diagram21.5.3 Derivation of the Expression for the Maintainability Function21.5.4 Maintainability Characteristics for Different Design Options21.6 Maintainability Engineering Management21.6.1 Role of the Maintainability Engineering Management Function21.6.2 MEMF Opportunities21.6.3 MEMF Obstacles21.6.4 Design Methods for Attaining 0570571571572572575576577577580585592593594594596
Contents21.6.5 Maintainability Engineering Management - Lessons Learned21.7 Concluding RemarksReferencesxxi603607610Part VII - Maintenance Safety, Environment and Human Error22 Safety and MaintenanceLiliane Pintelon and Peter N. Muchiri22.1 Setting the Scene22.2 Definitions22.2.1 Maintenance22.2.2 Safety22.2.3 Hazard22.2.4 Stimuli22.2.5 Accident22.3 The Maintenance Link to Safety22.3.1 The Role of Maintenance22.3.2 Safety During Maintenance22.3.3 Maintenance for Safety22.3.4 Human Errors in Maintenance22.3.5 Accident Causation Theories vs Maintenance22.4 Maintenance Policies and Concepts vs Safety22.4.1 Definitions22.4.2 Maintenance Actions22.4.3 Maintenance Policies22.4.4 Maintenance Concepts22.5 Maintenance Safety and Accident Prevention22.5.1 Methods of Accidents and Hazards Avoidance in Maintenance22.5.2 Analytical Approach22.5.3 The Engineering Approach22.5.4 Safety Culture22.5.5 Safety Legislations22.6 Safety MeasurementReferences23 Maintenance Quality and Environmental Performance Improvement:An Integrated ApproachAbdul Raouf23.1 Introduction23.2 Maintenance Quality23.2.1 Improving Maintenance Quality23.2.2 Benchmarking and Quality23.2.3 Maintenance Audit23.2.4 Improving Maintenance Quality Based on Stakeholder Feedback23.3 Lean Manufacturing - Maintenance Quality Relationship23.3.1 Basic Environmental Measure23.4 Integrated 0651655.656656656660
xxii Contents23.5 ConclusionReferences24 Industrial Asset Maintenance and Sustainabiiity Performance:Economical, Environmental, and Societal ImplicationsJayantha P. Liyanage, Fazleena Badurdeen, R.M. Chcmdima Ratnayake24.1 Introduction24.2 Industrial Activities and Sustainabiiity Trends24.3 Sustainabiiity Performance in Perspective24.4 Sustainabiiity Performance Framework: From Business to Asset24.5 Defining Maintenance Custodianship Within an Asset's SustainabiiityPerformance24.6 Generic Maintenance Impact Management Process24.7 Adapting an Effective Asset Maintenance Practice for Sustainabiiity24.8 68968925 Human Reliability and Error in MaintenanceB.S. Dhillon25.1 Introduction25.2 Terms and Definitions25.3 Human Reliability and Error in Maintenance-Related Facts, Figures,and Examples25.4 Occupational Stressors, Human Performance Effectiveness, andHuman Performance Reliability Function25.5 Human Error Occurrence Ways, Consequences, and Classifications,and Maintenance Error in System Life Cycle25.6 Reasons for the Occurrence of Human Error in Maintenance and TopHuman Problems in Maintenance25.7 Mathematical Models for Performing Maintenance Error Analysis inEngineering Systems25.7.1 Modell25.7.2 Model II25.8 Useful Guidelines to Reduce the Occurrence of Human Error inMaintenanceReferences69526 Human Error in Maintenance-A Design PerspectiveClive Nicholas26.1 Introduction26.2 Human Error in Aircraft Maintenance26.3 Significance of Maintenance Error26.4 Design Impact26.5 Analysis Required for Design Solutions26.5.1 Maintenance Tasks26.5.2 Maintenance Errors26.5.3 Causal 13717718721722724
Contents xxiii26.6 Design Strategies and Principles26.6.1 Appreciate the Maintainer's Perspective of the Aircraft26.6.2 Design for the Aircraft Maintenance Environment26.6.3 Protect the Aircraft and Protect the Maintainer26.6.4 Avoid Complexity of Maintenance Tasks26.6.5 Enable Adequate Maintenance Access26.6.6 Positively Standardise and Positively Differentiate26.6.7 Build Error Detection into the Maintenance Process26.7 734735737
Maintenance Management and Engineering Springer . Contents List of Contributors xxv Part I - Maintenance Organization 1 Maintenance Organization 3 Ahmed E. Haroun and Salih O. Duffuaa 1.1 Introduction 3 1.2 Maintenance Organization Objectives and Responsibility 5 1.3 Determinants of a Mainten
