Cover image for 100 years in maintenance and reliability : practical lessons from three lifetimes at process plants
Title:
100 years in maintenance and reliability : practical lessons from three lifetimes at process plants
Personal Author:
Publication Information:
New York, NY. : Industrial Press, 2008
Physical Description:
x, 363 p. : ill. ; 26 cm.
ISBN:
9780831133238
Added Author:

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30000010186352 TS192 N35 2007 Open Access Book Book
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30000010185142 TS192 N35 2008 Open Access Book Book
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30000003499229 TS192 N35 2008 Open Access Book Book
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Summary

Summary

This unique and practical book describes 42 real-life events and/or situations in the careers of the three authors from which they gained insights into the applicable best practices in maintenance and reliability. The authors explain the underlying philosophies where relevant, drawing on the teachings of the leading thinkers in leadership and management. Designed to share knowledge and experience with the readers, in a readily accessible fashion, this resource does not tell the readers what to do or how to do it; it merely explains the event or situation the authors faced, and how they dealt with it. Readers can choose whether they wish to adopt or adapt the authors' examples. These stories are dynamic illustrations of real life situations which readers will recognize in their own work situations. With a vast potential for improvements in reliability and maintenance performance in industry, these well proven approaches and best practices are sure to help stimulate improved performance on all fronts--safety and environmental, production, maintenance costs, and reputation!

Provides a logical organization with chapters grouped into six broad headings, enabling readers to choose the order in which they wish to absorb the lessons, which are based on the Shewhart-Deming Continuous Improvement cycle. In addition to the Plan-Schedule-Execute-Analyze elements, the authors have added Leadership and People to complete the suite. Each chapter has broadly similar sections, beginning with a Background to the events, going on to describe the key elements of the approach, and ending with Lessons and Principles. Underlying theories, philosophies or even detailed descriptions of methods are stripped out of the main chapters and described in Appendices, so that only those readers who wish to delve into details may do so. Contains a Book Summary which draws all the principles and lessons together, and gives references to the relevant chapters. Copiously illustrated, with charts, diagrams and tables which relate closely to the text.


Table of Contents

Charles J. Latino
Forewordp. vii
Part 1 Introduction
1 Introduction & Navigation Guidep. 3
2 The Locationsp. 7
Part 2 Leadership
3 Creating the Visionp. 15
4 Setting Objectivesp. 23
5 Changing Paradigms with Leadership and Expertisep. 29
6 Applying Best Business Practicesp. 38
7 Evaluating Contractors' Unit Ratesp. 57
8 Benchmarkingp. 65
Part 3 People
9 Staffing levelsp. 79
10 Integrating Inspection and Degradation Strategiesp. 87
11 Technician Training Challengep. 95
12 Competence Profilesp. 100
13 Operators & Maintainersp. 109
14 Building a Reliability Culturep. 119
15 Managing Surplus Staffp. 122
16 Retraining Surplus Staffp. 129
Part 4 Plan
17 Integrated Planningp. 135
18 Critical Path Planning Capabilityp. 141
19 Shutdown Managementp. 144
20 Electrical Maintenance Strategiesp. 153
21 Minor Maintenance by Operatorsp. 162
22 Relocating Machine Toolsp. 168
23 Painting Contract Strategyp. 183
Part 5 Schedule
24 Long Look-Ahead Planp. 191
25 Workload Managementp. 196
26 Infrastructure Maintenancep. 200
27 Workflow Managementp. 205
Part 6 Execute
28 Trip Testingp. 217
29 Work the Planp. 221
30 Keeping to Schedulep. 229
31 Operators as a Maintenance Resourcep. 235
32 Overtime Controlp. 240
33 Managing Contractorsp. 245
Part 7 Analyze
34 Reliability Engineering in New Projectsp. 257
35 Computing Reliability Datap. 265
36 Turnaround Performance Improvementsp. 272
37 Reducing Shutdown Durationp. 282
38 A Small Matter of Cleaningp. 291
39 Motor Maintenance Regimesp. 296
40 Boiler Feed-Water Pump Sealsp. 303
41 Cooling Water Pump Failuresp. 309
42 Heater Outlet Flue Gas Dampersp. 319
43 Laboratory Oven Failuresp. 325
44 Pump Reliabilityp. 335
45 Book Summaryp. 342
Glossaryp. 349
Indexp. 361