Handbook of Maintenance Management and Engineering

Transcription

1 Mohamed Ben-Daya Salih O. Duffuaa Abdul Raouf Jezdimir Knezevic Daoud Ait-Kadi Editors Handbook of Maintenance Management and Engineering Springer

2 Contents List of Contributors xxv Part I - Maintenance Organization 1 Maintenance Organization 3 Ahmed E. Haroun and Salih O. Duffuaa 1.1 Introduction Maintenance Organization Objectives and Responsibility Determinants of a Maintenance Organization Maintenance Capacity Planning Centralization vs Decentralization In-house vs Outsourcing Design of the Maintenance Organization Current Criteria for Organizational Change Criteria to Assess Organizational Effectiveness Basic Types of Organizational Models Material and Spare Parts Management Establishment of Authority and Reporting Quality of Leadership and Supervision Incentives Education and Training Management and Labor Relations Summary 15 References 15 2 Maintenance Productivity and Performance Measurement 17 Adityct Parida and Uday Kumar 2.1 Introduction Performance Measurement and Maintenance Productivity Maintenance Performance Measurement of Maintenance Productivity 23

3 xii Contents Maintenance Performance Indicator (MPI) MPM Issues MPM System MPI Standards and MPIs as in Use in Different Industries Nuclear Industry Maintenance Indicators by EFNMS SMRP Metrics Oil and Gas Industry Railway Industry Process Industry Utility Industry Auto-industry Related MPIs for the CEO Concluding Remarks 39 References 39 Part II - Methods and Tools in Maintenance 3 Failure Statistics 45 Mohamed Ben-Daya 3.1 Introduction Introduction to Probability Sample Spaces and Events Definition of Probability Probability Rules Conditional Probabilities Random Variables Probability Distributions Reliability and Failure Rate Functions Introduction Reliability Function Failure Rate Function Mean Time Between Failure (MTBF) Commonly Used Distributions The Binomial Distribution The Poisson Distribution The Normal Distribution The Lognormal Distribution The Exponential Distribution The Weibull Distribution Failure Statistics Types of Data Parameter Estimation 64 References 73 4 Failure Mode and Effect Analysis 75 Mohamed Ben-Daya 4.1 Introduction 75

4 Contents xiii 4.2 FMEA Defined FMEA Process FMEA Applications Related Tools Root Cause Analysis Pareto Chart Cause and Effect Diagram 87 References 90 Part III - Maintenance Control Systems 5 Maintenance Control 93 Salih О. Duffuaa and Ahmed E. Haroun 5.1 Introduction The Maintenance Control Function The Control Process Functional Structure of Maintenance Control Work Order System Basic Documentation for Work Order System Work Order System Flow Tools Necessary for Effective Maintenance Control System Work Control Cost Control Quality Control Plant Condition Control Effective Programs for Improving Maintenance Control Emergency Maintenance Reliability Improvement Total Productive Maintenance Computerized Maintenance Management and Information Technology Summary 112 References Guidelines for Budgeting and Costing Planned Maintenance Services 115 Mohamed Ali Mirghani 6.1 Introduction An Overview of Budgeting and Costing Systems Budgeting Systems Costing Systems Proposed Budgetary System Planned Maintenance Operating Budget Financial Budget The Budget Cycle Top Management Support Budget Performance Reports Planned Maintenance Job Costing 123

5 xiv Contents Standard Cost Elements of a Planned Maintenance Job Actual Cost Elements of a Planned Maintenance Job Total Cost of a Planned Maintenance Job Planned Maintenance Job Cost Variances Significant Cost Variances Summary and Conclusions 131 References Simulation Based Approaches for Maintenance Strategies Optimization Fouad Riane, Olivier Roux, Olivier Bas He, and Pierre Dehombreux 7.1 Introduction Reliability Models Estimation Regression and ML Methods Uncertainty Affecting Reliability Model Maintenance Performance Availability Model Costs Model Simulation Based Maintenance Framework Toward a Unified Framework Maintenance Strategies Uncertainty Affecting Maintenance Performances A Case Study Conclusion 152 References 152 Part IV - Maintenance Planning and Scheduling 8 Maintenance Forecasting and Capacity Planning 157 Hesham K. Alfares andsalih O. Duffuaa 8.1 Introduction Forecasting Basics Qualitative Forecasting Techniques The Delphi Method Quantitative Forecasting Techniques Simple Moving Averages Weighted Moving Average Regression Analysis Exponential Smoothing Seasonal Forecasting Box-Jenkins Time Series Models Error Analysis Forecasting Maintenance Workload Maintenance Capacity Planning Deterministic Approaches for Capacity Planning Modified Transportation Tableau Method Mathematical Programming Methods Stochastic Techniques for Capacity Planning 182

6 Contents xv Queuing Models Stochastic Simulation Summary 188 References Integrated Spare Parts Management 191 Claver Diallo, Daoud Ait-Kadi, and Anis Chelbi 9.1 Introduction Spare Parts Identification and Classification Determination of the Required Quantity of Spare Parts Recommendations Reliability and Availability Based Procedures Forecasting Procedure Simulation Inventory Control Policies Model with Known and Constant Demand and Lead-time (EOQ Model) Model with Constant Demand and Perishable Items Model with Random Demand and Lead-time Joint Maintenance and Provisioning Strategies Joint Replacement and Ordering Policy for a Spare Unit (One Unit Provisioning) Joint Replacement and Multiple Spare Parts Ordering Policy (Batch Provisioning) Inventory and Maintenance Policies for Reconditioned Spare Parts Age of Recovered Parts to be Used for Replacement Actions Review of Inventory Control Policies with Random Returns Collaborative Management of Spare Parts Access to Documentation and Knowledge Bases Lead-time Reduction Virtually Centralized Spare Parts Stock (Inventory Pooling) Joint Replenishment of Spare Parts Conclusion 218 References Turnaround Maintenance 223 Salih Duffuaa and Mohamed Ben-Daya 10.1 Introduction Turnaround Initiation Work Scope Long Lead Time Resources Contractors ТАМ Planning ТАМ Organization Site Logistics ТАМ Budget Quality and Safety Plans 231

7 xvi Contents Quality Plan Safety Plan ТАМ Communication Procedures ТАМ Execution ТАМ Closing and Final Report Conclusion 234 References Maintenance Planning and Scheduling 237 Umar M. Al-Turki 11.1 Introduction Strategic Planning in Maintenance Medium Range Planning Short Range Planning Maintenance Scheduling Elements of Sound Scheduling Maintenance Job Priority System Scheduling Techniques Gantt Charts and Scheduling Theory Project Scheduling Critical Path Method Program Evaluation Review Techniques (PERT) Scheduling Using Computers Summary 260 References Models for Production and Maintenance Planning in Stochastic Manufacturing Systems 263 E.K. Boukas 12.1 Introduction Problem Statement and Preliminary Results Dynamic Programming Approach Linear Programming Approach Conclusion 295 References 296 Part V - Maintenance Strategies 13 Inspection Strategies for Randomly Failing Systems 303 Anis Chelbi and Daoud Ait-Kadi 13.1 Introduction Notation Basic Inspection Model Problem Definition Working Assumptions and Mathematical Model Extensions of the Basic Model Inspection Models for Single Component Systems 308

8 Contents xvii 13.4 Inspection Models for Multi-component Systems Failure Tree Method Based Strategies Cases of Cold and Hot Stand-by Systems with Known and Partially Known Lifetime Distributions Case of Systems with Components Failure Dependency Conditional Maintenance Models Conditional Maintenance Models for Single Component Systems Conditional Maintenance Models for Multi-Component Systems Conclusion 331 References System Health Monitoring and Prognostics - A Review of Current Paradigmsand Practices 337 Ranganath Kothamasu, Samuel H. Huang, William H. VerDuin 14.1 Maintenance Strategies: Motivations for Health Monitoring Health Monitoring Paradigms Health Monitoring Tools and Techniques Reliability-based Maintenance Model-based Approach to FDI Signal-based FDI Statistical FDI/Maintenance Case Studies in System Monitoring and Control Organizations and Standards Summary and Research Directions 356 References Applied Maintenance Models 363 K. I to and T. Nakagawa 15.1 Introduction Missile Maintenance Expected Cost Optimal Inspection Policies Numerical Illustrations Phased Array Radar Maintenance Cyclic Maintenance Delayed Maintenance Numerical Illustrations Self-diagnosis for FADEC Double Module System Triple Module System N Module System Numerical Illustrations Co-generation System Maintenance Model and Assumptions Analysis Optimal Policy Numerical Illustration 391 References 392

9 xviii Contents 16 Reliability Centered Maintenance 397 Atiq Waliullah Siddiqui and Mohamed Ben-Daya 16.1 Introduction RCM Philosophy RCM Principles and Key Features RCM Goals and Benefits System, System Boundary, Interfaces and Interactions Failure and its Nature RCM Methodology Selecting Systems Selection and Collecting Information System Boundary Definition System Description and Functional Block Diagram System Functions and Functional Failure Failure Mode and Effective Analysis (FEMA) Logic or Decision Tree Analysis (LTA) Task Selection RCM Implementation Organizational Factors RCM Teams Scheduling Consideration and Training Conclusion 414 References Total Productive Maintenance 417 P.S. Ahuja 17.1 Introduction to TPM Evolution Towards TPM Need of TPM Basic Elements of TPM Roadmap for TPM Implementation An Ideal TPM Methodology Introduction Phase (Phase I) TPM Initiatives Implementation Phase (Phase II) Standardization Phase (Phase III) Barriers in TPM Implementation Success Factors for Effective TPM Implementation Summary 458 References Warranty and Maintenance 461 D.N. P. MurthyandN. Jack 18.1 Introduction Maintenance Modelling Reliability Types of Maintenance Failure Modelling 462

10 Contents xix 18.3 Warranties Base Warranties Classification of Base Warranties Warranty Servicing Cost Analysis Extended Warranties Link Between Warranty and Maintenance Taxonomy for Classification Warranty Servicing Involving Only CM Warranty Servicing Involving Both CM and PM Maintenance Logistics for Warranty Servicing Strategic Issues Tactical and Operational Issues Outsourcing of Maintenance for Warranty Servicing Agency Theory Conclusions and Topics for Future Research 476 References Delay Time Modeling for Optimized Inspection Intervals of Production Plant 479 Wenbin Wang 19.1 Introduction The DT Concept and Modeling Characteristics The DT Models for Complex Plant The Down Time/Cost Model Modeling E[N f ((i-\)t,it)\ and E[N s (it)] Under the Assumption of Perfect Inspections Modeling E[N f ((i-\)t,it)] and E[N s (it)] Under the Assumption of Imperfect Inspections Delay Time Model Parameters Estimation Introduction Complex System - Parameter Estimation A Case Example Other Developments in DT Modeling and Future Research Directions References Integrated E-maintenance and Intelligent Maintenance Systems 499 Jayantha P. Liyanage, Jay Lee, Chris tos Emmanouilidis, andjun Ni 20.1 Introduction Condition-based Maintenance Technology and the State of Development Integrated E-maintenance Solutions and Current Status Technical Framework for E-maintenance Watchdog Agent-based Intelligent Maintenance Systems R 2 M-PHM Platform System Architecture 512

11 xx Contents Toolbox for Multi-sensor Performance Assessment and Prognostics Maintenance Decision Support System Technology Integration for Advanced E-maintenance Generic ICT Interface Generic Interface Requirements for Watchdog Agents Systems-user Interface Needs Some Industrial Applications E-maintenance Solutions for Complex Industrial Assets Watchdog Technology for Product Life-cycle Design and Management Watchdog Technology to Trouble-shoot Bearing Degradation Challenges of E-maintenance Application Solutions Conclusion 538 References 539 Part VI - Maintainability and System Effectiveness 21 Maintainability and System Effectiveness 547 J. Knezevic 21.1 Introduction The Concept of Maintainability Maintainability Impact on System Effectiveness Maintainability Impact on Safety Undesirable Maintainability Practices Desirable Maintainability Practices Maintainability Analysis Measures of Maintaniablity Maintenance Labour-hour Factors Maintenance Frequency Factors Maintenance Cost Factors Related Maintenance Factors Empirical Data and Maintainability Measures Possible Approaches to Analysis of Existing Data Parametric Approach to Maintainability Data Distribution Approach to Maintainability Data Distribution Approach Maintainability Engineering Predictions Introduction Concept of the Maintainability Block Diagram Derivation of the Expression for the Maintainability Function Maintainability Characteristics for Different Design Options Maintainability Engineering Management Role of the Maintainability Engineering Management Function MEMF Opportunities MEMF Obstacles Design Methods for Attaining Maintainability 596

12 Contents xxi Maintainability Engineering Management - Lessons Learned Concluding Remarks 607 References 610 Part VII - Maintenance Safety, Environment and Human Error 22 Safety and Maintenance 613 Liliane Pintelon and Peter N. Muchiri 22.1 Setting the Scene Definitions Maintenance Safety Hazard Stimuli Accident The Maintenance Link to Safety The Role of Maintenance Safety During Maintenance Maintenance for Safety Human Errors in Maintenance Accident Causation Theories vs Maintenance Maintenance Policies and Concepts vs Safety Definitions Maintenance Actions Maintenance Policies Maintenance Concepts Maintenance Safety and Accident Prevention Methods of Accidents and Hazards Avoidance in Maintenance Analytical Approach The Engineering Approach Safety Culture Safety Legislations Safety Measurement 643 References Maintenance Quality and Environmental Performance Improvement: An Integrated Approach 649 Abdul Raouf 23.1 Introduction Maintenance Quality Improving Maintenance Quality Benchmarking and Quality Maintenance Audit Improving Maintenance Quality Based on Stakeholder Feedback Lean Manufacturing - Maintenance Quality Relationship Basic Environmental Measure Integrated Approach 660

13 xxii Contents 23.5 Conclusion 663 References Industrial Asset Maintenance and Sustainabiiity Performance: Economical, Environmental, and Societal Implications 665 Jayantha P. Liyanage, Fazleena Badurdeen, R.M. Chcmdima Ratnayake 24.1 Introduction Industrial Activities and Sustainabiiity Trends Sustainabiiity Performance in Perspective Sustainabiiity Performance Framework: From Business to Asset Defining Maintenance Custodianship Within an Asset's Sustainabiiity Performance Generic Maintenance Impact Management Process Adapting an Effective Asset Maintenance Practice for Sustainabiiity Conclusion 689 References Human Reliability and Error in Maintenance 695 B.S. Dhillon 25.1 Introduction Terms and Definitions Human Reliability and Error in Maintenance-Related Facts, Figures, and Examples Occupational Stressors, Human Performance Effectiveness, and Human Performance Reliability Function Human Error Occurrence Ways, Consequences, and Classifications, and Maintenance Error in System Life Cycle Reasons for the Occurrence of Human Error in Maintenance and Top Human Problems in Maintenance Mathematical Models for Performing Maintenance Error Analysis in Engineering Systems Modell Model II Useful Guidelines to Reduce the Occurrence of Human Error in Maintenance 707 References Human Error in Maintenance-A Design Perspective 711 Clive Nicholas 26.1 Introduction Human Error in Aircraft Maintenance Significance of Maintenance Error Design Impact Analysis Required for Design Solutions Maintenance Tasks Maintenance Errors Causal Factors 724

14 Contents xxiii 26.6 Design Strategies and Principles Appreciate the Maintainer's Perspective of the Aircraft Design for the Aircraft Maintenance Environment Protect the Aircraft and Protect the Maintainer Avoid Complexity of Maintenance Tasks Enable Adequate Maintenance Access Positively Standardise and Positively Differentiate Build Error Detection into the Maintenance Process Conclusion 734 References 735 Index. 737