2 Introduction mission statement of maintenance department role of the maintenance department reasons for improving maintenance methods objectives

of the maintenance department planned maintenance with preventive care the safety and health of workers and machines planning and scheduling controlling flexibility data collection and analysis 8 basic functions of the maintenance department maintenance service 11 effects of automation the challenge of upgraded technology and changing environment the maintenance manger what affects maintenance efficiency of maintenance manger 14 down time analysis down time control operator 17 maintenance man 22 calssification and design of maintenance system 22 different maintenance systems breakdown maintenance routine maintenance planned maintenance CMMS computerized maintenance management systems 26 preventive maintenance predictive condition based maintenance corrective maintenance shutdown maintenance design out maintenance design in maintenance 28 design out maintenance reliability centered maintenance contract maintenance RCM paper based methodology 30 why and how to design a suitable maintenance system criticality of equipment 32 down time costs utilization factor standby availability down stream effects hazards involved due to failure age of the plant 34 skill level available infrastructure and facilities other factors use of maintenance costs to decide criticality pareto law 42 organisation for maintenance william b cornell plunkett and attner pre requisites of an organisation team spirit the maintenance manger goals and objectives policy development of subordinates utilization of talent levels of organisation clear cut definitions of duties production vs. maintenance 46 functions of a maintenance manger effectiveness of maintenance organisation objectives of the organizational design types of organizations decentralized centralized partially decentralized management hierarchies communication and feedback within and organisation 54 operations maintenance liaison communication within the maintenance department

63

66

70

72

76 76

86

91

97

106

labor turnover in maintenance department weekend working trend salary conditions frustration working conditions predictive or condition based maintenance definition of condition based maintenance objective of condition based maintenance increased availability and reliability of plant safety and avoidance of hazards optimization of maintenance costs benefits of condition based maintenance methods of condition monitoring online inspection off line inspection application of condition monitoring importance of equipment with respect to the process or production whether hazards are involved in case of failure down stream effects cost of down time cost of condition monitoring implementing the condition based maintenance plant survey selection of machines for CBM selection of condition monitoring technique establishing a monitoring program me data collection and analysis training to maintenance personnel levels of monitoring various analysis techniques vibration monitoring visual monitoring magnification providing access slow motion or freeze motion temperature monitoring defect detection by temperature monitoring for surface temperature measurement shock pulse monitoring bearing analysis lubrication analysis wear debris collection common contaminants and possible diagnosis fixed monitoring system centralized surveillance overhauls and shutdowns proactive approach to shutdowns the type of work executed MTBPL mean time between production loss MPL mean production loss finalized scheduled for the shutdown work list shutdown management quality of the shutdown work planning overhauling process planning material planning manufacturing of spare parts just before shutdown starts one bay before the shutdown the plant shutdown start up of plant post overhaul phase role of overhaul manger opportunity maintenance network analysis PERT CPM total planned maintenance components of a planned maintenance system assets register maintenance schedule work specification resourcing schedule maintenance records maintenance support organisation liaison with production department

108

111

117

121

127

132

141

145

155

planned overhaul maintenance cost control training to maintenance personnel management information system maintenance control system analysis of maintenance records disposal of equipment standardization of spares and equipments spare part manufacture selling of non moving spares and materials asset register cardex system maintenance schedules work specification resourcing schedule maintenance records history card defect analysis record downtime record and analysis maintenance work order equipment history card defect analysis record down time analysis sample of work order card quality control planned lubrication maintenance support organisation liaison with the user planned shutdowns maintenance controls elements of maintenance control system work order release system technical literature drawing spares and materials with tools and tackles quality of work progress of work feedback of information cost control stores requisition slip controlling maintenance expenses control methodology analysis of maintenance records model control system for planned maintenance control over the maintenance resources increased inventory control elimination of waste of business processes increased accuracy in maintenance budgeting reduced maintenance costs inspection and lubrication what to check check list for mud pump at ETP fan at boiler frequency of inspection planning for inspection inspection infrastructure inspection work order lubrication objectives of lubrication types of lubricants essentials of well planned lubrication system right identification of lubrication points right selection of lubricant right frequency of lubrication right quantity of lubricant right care and storage of lubricant lubrication planning survey lubricant quantities lubrication plan lubrication In a store hanger schedule of lubrication training lubrication scheduling and implementation maintenance training need for training

training policy manual 158 how to get value from training value added actions by the manager identify development need have an intimate dialogue with attendees assess infrastructure ensure training is appropriate whom to train worker leave supervisor level 162 executive training training methodology who will train tools of training MRP 170 safety management and accident prevention factory act safety considerations for a new project safety considerations during planning stage safety during installation safety during commissioning 172 safety during maintenance safety of plant and people accidents 175 cost of an accident cost to the individual victim cost to the employer direct costs indirect costs how accidents can be minimized safety management red cross society 186 maintenance support systems engineering store organisation codification of spares documents handled by stores lubrication handling spare parts rationalization vendor assistance overhaul by exchange 192 contract maintenance single contract tasks repetitive tasks provision of contract labor only care to be taken before employing contact labor product support an ideal product support system 198 technical manuals user assistance information technical data operating information technical specifications handling instructions maintenance instructions maintenance schedules spare parts lists modifications simplified technical instructions caterpillar tractor company ILSAM international language for servicing and maintenance how to prepare maintenance manuals how to write specifications 204 spare parts lists fault diagnostic charts system documentation product support for civil installation buildings service installation in the buildings microfilming of data drawing libraries 213 spare parts management AGREE advisory group formed on reliability of electronic equipment MTTF mean time to failure MTBF mean time between failure failure analysis

216

222

232

238

246

254

257

261

262

reasons of failure causes of failure bathtub curve teething problems inspection of spares acceptance sampling method procurement of spares right quantity EOQ right time right price right quality right source right place of delivery CPI chemical process industries right systems import substitution EAM enterprise asset management cost reduction spares characteristics of spare parts categories of spare parts maintenance spares insurance spare parts capital spares routable spare parts overhauling spares commissioning spare parts cost control in spare parts cost of spare part inventory techniques of cost control choice of equipment some tips to reduce inventory cost lead time analysis codification of spare parts value analysis standardization disposal of obsolete items reconditioning of spares ABC analysis CIE control by importance and exception advantages of ABC control VED analysis cost control techniques total productive maintenance TPM part 1 WCM worl class manufacturing TPM total productive maintenance what is TPM concepts and objectives of TPM objectives of TPM TPM and TQM benefits of TPM OPE increase of productivity calculations of OEE overall equipment efficiency equipment losses equipment failure set up losses equipment idling and minor stoppages reduced running speeds defect in process products reduced equipment yield principles of TPM improving equipment effectiveness by targeting the major losses involving operators in the daily routine maintenance of their equipment improving maintenance efficiency and effectiveness CMMS computerized maintenance management systems training to improve skills of everyone involved life cycle equipment management and maintenance prevention design winning with team work focused on common goals pillars of TPM pillar 1 5 S seiri seiton seiso seiketsu

266

272

277

281

284

298

298

300

301

303

307

310

313

317

shitsuke advantages of 5 S pillar 2 jishu hozen autonomous maintenance AM autonomous maintenance objectives hartmann total productive maintenance TPM part 2 wang and lee hartmann remaining pillars of TPM pillar 3 kaizen sixteen major losses in an organisation kaizen principles tools used in kaizen foundation of kaizen method massai imai gemba kaizen pillar 4 planned maintenance MTBF mean time between failure pillar 5 quality maintenance pillar 6 training objectives steps in training syllabus for training pillar 7 office TPM kaizen in office TPM benefits of office TPM pillar 8 safety health and environment objectives activities positive factors for success of TPM don russell negative factors which affect success of TPM OEE overall equipment effectiveness use of computers and evolution of maintenance system computer controlled system how computer can be used asset management planning of maintenance cost control spares requirement planning resource evaluation manpower effectiveness ratio benefits of CMMS expected outputs from computer CMM software or CMMS EAM enterprise asset management CAFM computer aided facility management FMS CAFM MMS guidelines for selecting CMMS software work order spare parts control maintenance history and reporting MTTR PM system general functions of maintenance department fields of working managerial responsibilities expectations by the top management the present conditions evaluation of maintenance function subjective evaluation maintenance function objective evaluation future challenges