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To manufacture quality products or provide services at competitive prices is essential to survive in today’s business climate. We are forced to look for better ways of doing things on continual basis. To meet customer’s needs – on their schedule – requires (high) availability and reliability of equipment and systems when they are needed. But it is not as simple as putting something into effect. To truly realize a best practice requires learning, re-learning, benchmarking and implementing better ways of ensuring high reliability and availability of equipment and systems.
Maintenance & Reliability Best Practices is designed to support that learning process. Written by professionals with 60 plus years of shop floor and management experience in a variety of industries, this practical resource will help seasoned professionals and novices understand the basic principles of maintenance and reliability. Written in an easy-to-read format, each chapter discusses the concepts with specific questions and answers. Each topic answers the what, why or how of the topic being presented. Understanding and implementing M&R practices in a cost-effective way is essential. This is perfect book for all in the work force of an organization who need to have a solid understanding of M&R.
Introducing Best Practices What Is a Best Practice Understanding Maintenance and Reliability Examples of Maintenance and Reliability Benchmarks Basic Test on Maintenance and Reliability Knowledge Key Terms and Definitions Summary References and Suggested Reading Culture and Leadership Introduction Leadership and Organizational Culture Strategic Framework: Vision, Mission, and Goals Reliability Culture Summary References and Suggested Reading Understanding Maintenance Introduction Maintenance Work Tasks Other Maintenance Practices Maintenance Quality and Tasks Optimization Measuring Maintenance Performance Summary References and Suggested Reading Work Management: Planning and Scheduling Introduction Work Flow and Roles Planning Process Scheduling Process Turnaround and Shutdowns Measures of Performance Summary References and Suggested Reading Materials, Parts, and Inventory Management li>Introduction Types of Inventory Physical Layout and Storage Equipment Optimizing Tools and Techniques Performance Measures and Indicators Summary References and Suggested Reading Measuring and Designing for Reliability and Maintainability Introduction Defining and Measuring Reliability and Other Terms Designing and Building for Maintenance and Reliability Summary References and Suggested Reading The Role of Operations Introduction The Role of Operations Total Productive Maintenance (TPM) Workplace Organization: 5 S Performance Measures: Metrics Summary References and Suggested Reading PM Optimization Introduction Understanding Failure PM Optimizing Tools Summary References and Suggested Reading Managing Performance Introduction Identifying Performance Measures Benchmarking and Benchmarks Data Collection and Data Quality Summary References and Suggested Reading Workforce Management Introduction Employee Life Cycle Understanding the Generation Gap People Development Workforce Management Summary References and Suggested Reading M & R Analysis Tools Introduction Analysis Tools Computerized Maintenance Management System Summary References and Suggested Reading Current Trends and Practices Arc Flash Hazards and Prevention Communication and Problem Solving Skills Energy Conservation and Green Initiative Lean Management and Maintenance Safety and Reliability Systems Engineering and Configuration Management References and Suggested Reading Answer Key and Explanations Supplemental Glossary Index
Introducing Best Practices
Culture and Leadership
Understanding Maintenance
Work Management: Planning and Scheduling
Materials, Parts, and Inventory Management
Measuring and Designing for Reliability and Maintainability
The Role of Operations
PM Optimization
Managing Performance
Workforce Management
M & R Analysis Tools
Current Trends and Practices
Answer Key and Explanations
Supplemental Glossary
Index
Ramesh Gulati is a seasoned veteran of maintainability-reliability pursuits who has also developed expertise in the practice of system safety. He deals with these and many other maintenance and reliability-related concepts in this new, very readable, and almost entertaining textbook. Concepts and analytical techniques are walked through at an easy pace, from reliability block diagramming, to failure modes and effects analysis, and reliabilitycentered maintenance, and many an analytical technique along the way.
This is a kind book, a gentle book, a readable book. The format is designed for ease of use as a reference text. And as to content, the reader is not pummeled with flashy mathematics that attempt to show that one method of computing mean time to failure is better than another. The math that is used is straightforward in its presentation, truly functional, and easily followed. Graphic aids to understanding abound. Many are of kinds not seen before in the numerous standard texts on reliability. Most chapters include sections titled “Key Terms and Definitions,” introducing brief working definitions ofthe special terms that are used. Many practical problems are presented and worked through in bite-sized steps with as-we-go explanations presented as further tutorial aids. These and other features make the book well suited both for classroom use and as a self-help educational tool.
The often confused relationship between reliability and failure probability is very tidily presented here. For the believer that employing sound principles of reliability engineering replaces the practice of system safety, a wonderful epiphany emerges, unsaid but compellingly imbedded between the lines of these 416 pages. (A hand grenade may be very reliable; is it safe?)
Scattered lines disclose author Gulati’s personal view on the practice of safety engineering. Examples: “Reliable plants are safe plants and safe plants are reliable plants”; “…organizations that are reliable with excellent maintenance practices will have lower injury rates. The same behavior and practices that improve plant operations and reliability also reduce injuries.” And, of direct safety engineering value, an entire section is devoted to arc flash hazards and their prevention.
For the safety engineer who wants just one very practical book on maintenance and reliability engineering on his reference shelf, this is now the one to have."
P. L. Clemens
