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