Maintenance and Reliability Best Practices. Ramesh Gulati
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Overall Equipment Effectiveness
Measures of Performance
Summary
Self-Assessment Questions
References and Suggested Reading
CHAPTER 8
Maintenance Optimization
Understanding Failures and Maintenance Strategies
Key Terms and Definitions
Maintenance Strategy—RCM
Maintenance Strategy—CBM
Other Maintenance Strategies
Summary
Self-Assessment Questions
References and Suggested Reading
CHAPTER 9
Managing Performance
Key Terms and Definitions
Identifying Performance Measures
Data Collection and Data Quality
Benchmarking and Benchmarks
Summary
Self-Assessment Questions
References and Suggested Reading
CHAPTER 10
Workforce Management
Employee Life Cycle
Key Terms and Definitions
Understanding the Generation Gap
Communication Skills
People Development
Resource Management and Organization Structure
Measures of Performance
Summary
Self-Assessment Questions
References and Suggested Reading
CHAPTER 11
Problem Solving and Improvement Tools
Problem-Solving Tools
Key Terms and Definitions
Six Sigma and Quality Tools
Lean Tools
Improvement Strategies and Practices
Defect Elimination
Summary
Self-Assessment Questions
References and Suggested Reading
CHAPTER 12
Standards, Standardization, and Certification
Key Terms and Definitions
Codes, Standards, and Standardization
Management-Process Standards
Implementing Asset Management and Other Standards
Benefits of Standards
Summary
Self-Assessment Questions
References and Suggested Reading
CHAPTER 13
Current Trends and Practices
Sustainability, Energy Management, and the Green Initiative
Key Terms and Definitions
Safety Management
Risk and Project Management
Corrosion Control
Systems Engineering and Configuration Management
Industry 4.0, Digitalization, and the Factory of the Future
Stress, Wellness, and Productivity
Summary
Self-Assessment Questions
References and Suggested Reading
APPENDIX A
Basic Test on Maintenance and Reliability Knowledge: Answers and Explanations
APPENDIX B
SMRP/CMRP Body of Knowledge (BoK) for Maintenance & Reliability Professionals
APPENDIX C
Uptime Elements and Asset Life-Cycle Management
Index
The Mars rovers Spirit and Opportunity were launched individually in the summer of 2003 and touched down in January of 2004 in different regions of the planet. Each was equipped with a panoramic camera, a macro camera, spectrometers for identifying rocks and minerals, and a little drill for taking samples. The goal was to operate for 90 days, traveling about 40 meters each day and ultimately covering about a kilometer. Both exceeded those goals by incredible amounts. Spirit ended up traveling about 7.7 kilometers and lasting about 7 years.
Opportunity outshone its twin, going some 45 kilometers over 14 years.
No maintenance! High reliability.
The best practice for maintenance is zero. A maintenance-free asset is a dream come true for asset owners. As Ramesh Gulati has taught us for years, the time to influence such an outcome is in early asset life cycles such as specification, design, creation/build and commissioning. The required maintenance is locked in place once the asset begins its operating life. One’s influence on reliability, sustainability, safety, and total cost of ownership are limited after commissioning.
Yet, most assets are not maintenance-free. You will have to read 10 Rights of Asset Management (ISBN 978-1-941872-83-3) to learn more about the benefits of Reliability-Centered Design (RCD) as we refer to it in Uptime Elements Reliability Framework and Asset Management System or Design for Reliability (DFR) as Ramesh and his colleagues refer to it.
The issues around determining maintenance requirements for an asset were settled over 40 years ago with Nolan and Heaps seminal work “Reliability–Centered Maintenance” or RCM, commissioned by the Department of Defense in collaboration with United Airlines. The result of a thorough RCM analysis is a “technically valid” and “economically feasible” preventive maintenance strategy that is aimed at safely ensuring that the asset or system will deliver its function at the lowest possible cost.
Easy to say, much more challenging to do. Reliabilityweb research indicates that over 70% of maintenance improvement initiatives fail to generate sustainable business success, meaning, it never shows up on the financial statement.
In this book, Ramesh Gulati takes us on a 360-degree journey that includes technical approaches, effective processes, and, most importantly, people in order to reverse the trend of failed improvement efforts with proven strategies and tactics.
Unlike many authors, Ramesh is both a subject matter expert and an experienced master practitioner with a 40+ year record of highperformance reliability results. He has added so much value in various maintenance and reliability communities by sharing his own knowledge and through encouraging