RCM--Gateway to World Class Maintenance

ISBN-10: 075067461X
ISBN-13: 9780750674614
Edition: 2nd 2002
List price: $83.95 Buy it from $74.56
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Description: Completely reorganised and comprehensively rewritten for its second edition, this guide to reliability-centred maintenance develops techniques which are practised by over 250 affiliated organisations worldwide.

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Book details

List price: $83.95
Edition: 2nd
Copyright year: 2002
Publisher: Elsevier Science & Technology Books
Publication date: 11/11/2003
Binding: Hardcover
Pages: 337
Size: 6.00" wide x 9.00" long x 1.00" tall
Weight: 1.584
Language: English

Completely reorganised and comprehensively rewritten for its second edition, this guide to reliability-centred maintenance develops techniques which are practised by over 250 affiliated organisations worldwide.

Foreword
Preface
Acknowledgments
World Class Maintenance (WCM)--Opportunity and Challenge
Some Historical Aspects
Some Common Maintenance Problems
Proliferation of "Solutions"
The Acronym Parade
Benchmarking and Best Practices--Help or Hindrance?
Maintenance Optimization--An Emerging Vision
The Motivating Factor
The Traditional Maintenance Mindset
Rethinking Maintenance Strategy
Focusing Resources--The 80/20 Rule
World Class Maintenance (WCM)--Our Approach
Preventive Maintenance--Definition and Structure
What is Preventive Maintenance?
Why Do Preventive Maintenance?
Preventive Maintenance Task Categories
Time-Directed (TD)
Condition-Directed (CD)
Failure-Finding (FF)
CD Versus FF--A Distinction
Run-To-Failure (RTF)
Preventive Maintenance Program Development
Current PM Development Practices and Myths
PM Program Elements
The "R" in RCM--Pertinent Reliability Theory and Application
Introduction
Reliability and Probabilistic Concepts
Reliability in Practice
Some Key Elements of Reliability Theory
Failure Mode and Effects Analysis (FMEA)
Availability and Preventive Maintenance
RCM--A Proven Approach
Some Historical Background
The Bathtub Curve Fallacy
The Birth of RCM
What is RCM?
Feature 1
Feature 2
Feature 3
Feature 4
The Four Features--A Summary
Some Cost-Benefit Considerations
RCM Methodology--The Systems Analysis Process
Some Preliminary Remarks
Step 1--System Selection and Information Collection
Level of Assembly
System Selection
Information Collection
Step 2--System Boundary Definition
Step 3--System Description and Functional Block Diagram
Step 3-1--System Description
Step 3-2--Functional Block Diagram
Step 3-3--IN/OUT Interfaces
Step 3-4--System Work Breakdown Structure (SWBS)
Step 3-5--Equipment History
Step 4--System Functions and Functional Failures
Step 5--Failure Mode and Effects Analysis
Functional Failure-Equipment Matrix
The FMEA
Redundancy--General Rule
Redundancy--Alarm and Protection Logic
Step 6--Logic (Decision) Tree Analysis (LTA)
Step 7--Task Selection
Step 7-1--The Task Selection Process
Step 7-2--Sanity Check
Step 7-3--Task Comparison
Task Interval and Age Exploration
Items of Interest (IOI)
Illustrating RCM--A Simple Example (Swimming Pool Maintenance)
Step 1--System Selection and Information Collection
System Selection
Information Collection
Step 2--System Boundary Definition
Step 3--System Description and Functional Block Diagram
Step 3-1--System Description
Step 3-2--Functional Block Diagram
Step 3-3--IN/OUT Interfaces
Step 3-4--System Work Breakdown Structure (SWBS)
Step 3-5--Equipment History
Step 4--System Functions and Functional Failures
Step 5--Failure Mode and Effects Analysis
Step 6--Logic (Decision) Tree Analysis
Step 7--Task Selection
Step 7-1--Task Selection Process
Step 7-2--Sanity Check
Step 7-3--Task Comparison
Alternative Analysis Methods
Reducing Analysis Cost
Abbreviated Classical RCM Process
Step 1--System Selection and Information Collection
Step 2--System Boundary Definition
Step 3--System Description and Functional Block Diagram
Step 4--Functions and Functional Failures
Step 5--Failure Mode and Effects Analysis
Step 6--Logic (Decision) Tree Analysis (LTA)
Step 7--Task Selection
Items of Interest (IOI)
Experience-Centered Maintenance (ECM) Process
Part A
Part B
Part C
Implementation--Carrying RCM to the Floor
Historical Problems and Hurdles
Equipment-To-Function Hurdle
Organizational Hurdle
Run-To-Failure Hurdle
CD and FF Hurdle
Sacred Cows Hurdle
Labor Reduction Hurdle
PM Task Procedures Hurdle
Labor and Material Adjustment Hurdle
Gearing for Success
Plan
Do
Check
Act
Interfacing with the CMMS
Requirements for CMMS Integrated Support of RCM Activities
Developing Effective and Useful Task Procedures
RCM Rollup
Procedural Development
RCM Lessons Learned
Organizational Factors
The Structure Factor
The Decision Factor
The Financial Factor
The Buy-In Factor
RCM Teams
Resource Allocation
Team Makeup
Personnel Selection
Facilitator Role
Scheduling Considerations
Training
System Selection
Using IOIs (Items of Interest)
O&M Peer Acceptance
Program Management Considerations
Feedback to Management
Using Quantitative Reliability Data
Information Traceability and Coding
Key Factors in Success--and Failure
The Living RCM Program
Definition and Need
The Four Factors of The Living RCM Program
Adjustments to the Baseline RCM Analysis Results
Plant Modifications
New Information
Program Measurement
Reviewing The Living RCM Program
Living RCM Program Process
Software Support
RCM Software--A Historical Journey
An Observation
Reducing RCM Analysis Effort and Cost
Useful Attributes and Capabilities
RCM Software--Our Pick
Industrial Experience with Classical RCM
Selected Component PM Task Comparisons
Selected Case History Studies
Three Mile Island--Unit 1 Nuclear Power Plant
MidAmerican Energy--Power Plant Coal Processing
Tennessee Valley Authority (TVA)--Cumberland Plant FGD
Georgia-Pacific Corporation--Leaf River Pulp Operations
Boeing Commercial Airplane--Frederickson Wing Responsibility Center
Arnold Engineering Development Center (AEDC)--Von Karman Gas Dynamics Facility
NASA--Ames Research Center/12 ft Pressure Tunnel (PWT)
List of Acronyms
The Mathematics of Basic Reliability Theory
The Economic Value of Preventive Maintenance
References
Index
About the Authors

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