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Table Of Contents

1.1 Introduction
1.2.1 Definition of Maintenance
1.2.2 Objectives and Functions of Maintenance
1.3.1 Quality Aspects in Maintenance
1.3.2 Maintenance Organisation
1.3.3 Initial Level
1.3.4 Repeatable Level
1.3.5 Defined Level
1.3.6 Managed Level
1.3.7 Optimized Level
1.4.1 Training Strategy
1.4.2 Work Management
1.4.3 Resources Management
1.4.4 Supervisory Review
1.4.5 Quality Assurance
1.4.6 Subcontract Management
1.4.7 Commitment of the Maintenance Personnel
1.4.8 Verification of Implementation
1.4.9 Metrics and Process Improvement
1.5.1 Maintenance Management Perspectives
1.5.2 Types of Maintenance
1.5.3 Preventive Maintenance
1.5.4 Shut-down Maintenance
1.5.5 Opportunistic Maintenance
1.8 Answers
2.1 Introduction
2.2 Man Power
2.3.1.1 Inventory Costs
2.3.1.2 How Much to Order?
2.3.1.3 When to Order?
2.3.2 Selective Inventory Control Procedures
2.3.3.1 The Bill of Materials
2.3.3.2 Master production Schedule
2.3.3.3 Inventory Status File
2.3.3.4 Requirements Pegging
2.3.3.5 Rescheduling Process
2.4 Tools and Facilities
2.5 Effect of Maintenance Types on Resources
2.6 Summary
2.7 Terminal Questions
2.8 Answers
3.1 Introduction
3.2.1 Equipment Maintenance Function
3.2.2 Work order management subsystem
3.2.3 Inventory management function
3.2.4 Vendor management function
3.2.5 Subcontractor management function
3.2.6 General Information Systems Specifications
3.3 Work Management Process
3.4 Summary
3.5 Terminal Questions
3.6 Answers
4.1 Introduction
4.2 The Maintenance Function
4.3.1 Corrective or Breakdown Maintenance
4.4.1 Breakdown-time Distribution
4.4.2 Preventive versus Breakdown Maintenance (Single Machine)
4.5 Summary
4.6 Terminal Questions
4.7 Answers
5.1 Introduction
5.2 Functions & Feature of Maintenance Engineering
5.3.1.1 Advantages
5.3.1.2 Disadvantages
5.3.2.1 Characteristics of Planned Maintenance
5.3.2.2 Advantages of Planned Maintenance
5.3.3.1 Characteristics of Break-down Maintenance System
5.3.3.2 Objectives of BD/Corrective Maintenance
5.3.3.3 Advantages
5.3.3.4 Disadvantages
5.3.4.1 Preventive Maintenance System is
5.3.4.2 Features of PM
5.3.4.3 Requirements of Preventive Maintenance Program
5.3.4.4 Steps involved in Preventive Maintenance
5.3.4.5 Advantages of Preventive Maintenance
5.3.4.6 Disadvantages/limitations
5.3.4.7 Differences between Corrective and Preventive Maintenance
5.3.5 Predictive Maintenance
5.3.6.1 Condition Monitoring Methods
5.3.6.2 Implementation of Condition Based Maintenance: Involves:
5.3.6.3 Advantages
5.3.6.4 Disadvantages
5.4 Summary
5.5 Terminal Questions
6.1 Introduction
6.2 Functions of Maintenance Planning
6.3 Planning Vision & Mission
6.4 Functions of Maintenance Planner
6.5 Benefit of Planning
6.6 Planning System
6.7 How Much Planning Will Help?
6.8 Productivity, Specialization & Coordination of Planning
6.9 Maintenance Planning Principles
6.10 Planning Preventive & Predictive Maintenance, Projects
6.11 Summary of Maintenance Planning
6.12 Maintenance Scheduling Principles
6.13 Six Maintenance Scheduling Principles
6.14 Summary of Maintenance Scheduling
6.15 Terminal Questions
6.16 Answers
7.1 Introduction
7.2 Planner’s Function In Maintenance & Benefits
7.3 Organization & Processes
7.4 Benefits of Using ‘Ums’ with Planner’s Functions
7.5 Universal Principles for Higher Productive Maintenance
7.6.1 Universal Maintenance Standards [UMS]
7.6.2 Five Levels of Data in Ums 1) Basic Motions
7.7 ACE Team Benchmarking Process
7.8 Overall Craft Effectiveness [OCE] & Its Measurement
7.9 Summary
7.10 Terminal Questions
8.1 Introduction
8.2 Documentation Strategy
8.3.1 Role of the Document Controller
8.3.2 Types of QMS Documents
8.3.3 Document Numbering
8.3.4 Document Versioning
8.3.5 Document Content
8.4 QMS Documentation Process
8.5 Summary
8.6 Terminal Questions
8.7 Answers
9.1 Introduction
9.2 Functional Reliability of Facilities
9.3 Weibull Distribution Curve [Failure & Its Analysis]
9.4 Life of Equipment
9.5 Critical Analysis
9.6 Maintenance Performance Ratios
9.7 Maintenance Systems
9.8 Reliability and Availability Concepts
9.9 How Good Is ‘Reliability Performance’?
9.10 Maintenance Economics
9.11 Preventive Vs Breakdown Maintenance
9.12 Measurement of Maintenance Performance
9.13 Asset Life Cycle Management
9.14 Equipment Replacement Plans
9.15 Depreciation & Capital Expenditure based on Life Cycle
9.16 Summary
9.17 Terminal Questions
9.18 Answers
10.1 Introduction
10.2 Total Productive Maintenance [TPM]
10.3 Goals
10.4 Objectives of TPM
10.5 TPM-Its Features
10.6 Evolution of Maintenance Methods
10.7 Other Related Issues
10.8.1 Objectives of OEE:
10.8.2 OEE example:
10.9 Types of Losses (16)
10.10 Zero-Loss Concept:
10.11 Implementation of TPM
10.12.1 Pillar-1: Autonomous Maintenance: (Jishu – Hozen)
10.12.2 Pillar-2.Kobetsu Kaizen (Focussed Improvements)
10.12.3 Pillar: 3: Planned Maintenance [Pm] For Zero Loss
10.12.4 Pillar-4-Quality Maintenance for Zero Defects
10.12.5 Pillar-5-Development Management
10.12.6 Pillar-6-Trining & Education [Flow Of Controls]
10.12.7 Pillar-7: Safety, Health & Environment [Zero Accidents]
10.12.8 Pilar-8-Office Tpm [Raise Levels & Select Other Areas]
10.13 Relevance of TPM to TQM Framework
10.14 Benefits of TPM
10.15 Role Of TPM In World Class Manufacturing
10.16 Summary
10.17 Terminal Questions
10.18 Answers
11. Defects and improved quality
12. Ability to identify the cause of break downs
13. Ref. 10.12.3
14. Ref. 10.12.7
15. Ref. 10.13
16. Ref. 10.14
17. Ref. 10.15
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Om 0006

Om 0006

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Published by Nikhil Arora

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Published by: Nikhil Arora on Jun 23, 2011
Copyright:Attribution Non-commercial

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