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| موضوع: كتاب Maintenance for Industrial Systems السبت 30 سبتمبر 2023, 2:28 am | |
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أخواني في الله أحضرت لكم كتاب Maintenance for Industrial Systems With 504 figures and 174 tables Riccardo Manzini , Alberto Regattieri , Hoang Pham , Emilio Ferrari
و المحتوى كما يلي :
1 A New Framework for Productivity in Production Systems 1 1.1 Introduction 1 1.2 A Multiobjective Scenario 2 1.2.1 Product Variety . 3 1.2.2 Product Quality . 3 1.3 Production System Design Framework 4 1.4 Models, Methods, and Technologies for Industrial Management 5 1.4.1 The Product and Its Main Features . 5 1.4.2 Reduction of Unremunerated Complexity: The Case of Southwest Airlines . 6 1.4.3 The Production Process and Its Main Features . 7 1.4.4 The Choice of Production Plant 7 1.5 Design, Management, and Control of Production Systems . 10 1.5.1 Demand Analysis . 10 1.5.2 Product Design . 10 1.5.3 Process and System Design . 10 1.5.4 Role of Maintenance in the Design of a Production System 11 1.5.5 Material Handling Device Design 11 1.5.6 System Validation and Profit Evaluation 11 1.5.7 Project Planning and Scheduling . 11 1.5.8 New Versus Existing Production Systems . 11 1.6 Production System Management Processes for Productivity 13 1.6.1 Inventory and Purchasing Management . 14 1.6.2 Production Planning . 14 1.6.3 Distribution Management . 14 1.7 Research into Productivity and Maintenance Systems . 14 xixii Contents 2 Quality Management Systems and Statistical Quality Control 17 2.1 Introduction to Quality Management Systems 17 2.2 International Standards and Specifications . 19 2.3 ISO Standards for Quality Management and Assessment . 19 2.3.1 Quality Audit, Conformity, and Certification . 19 2.3.2 Environmental Standards . 21 2.4 Introduction to Statistical Methods for Quality Control 23 2.4.1 The Central Limit Theorem . 23 2.4.2 Terms and Definition in Statistical Quality Control . 24 2.5 Histograms . 25 2.6 Control Charts 25 2.7 Control Charts for Means . 26 2.7.1 The R-Chart 26 2.7.2 Numerical Example, R-Chart 29 2.7.3 The xN-Chart 29 2.7.4 Numerical Example, xN-Chart 30 2.7.5 The s-Chart 30 2.7.6 Numerical Example, s-Chart and xN-Chart . 33 2.8 Control Charts for Attribute Data 33 2.8.1 The p-Chart 35 2.8.2 Numerical Example, p-Chart 36 2.8.3 The np-Chart . 37 2.8.4 Numerical Example, np-Chart . 37 2.8.5 The c-Chart 37 2.8.6 Numerical Example, c-Chart 39 2.8.7 The u-Chart 40 2.8.8 Numerical Example, u-Chart 40 2.9 Capability Analysis 40 2.9.1 Numerical Example, Capability Analysis and Normal Probability 42 2.9.2 Numerical Examples, Capability Analysis and Nonnormal Probability . 46 2.10 Six Sigma 48 2.10.1 Numerical Examples . 51 2.10.2 Six Sigma in the Service Sector. Thermal Water Treatments for Health and Fitness 51 3 Safety and Risk Assessment 53 3.1 Introduction to Safety Management 53 3.2 Terms and Definitions. Hazard Versus Risk 54 3.3 Risk Assessment and Risk Reduction . 57 3.4 Classification of Risks . 58 3.5 Protective and Preventive Actions 60 3.6 Risk Assessment, Risk Reduction, and Maintenance 63 3.7 Standards and Specifications 63Contents xiii 4 Introduction to Maintenance in Production Systems 65 4.1 Maintenance and Maintenance Management . 65 4.2 The Production Process and the Maintenance Process . 66 4.3 Maintenance and Integration 69 4.4 Maintenance Workflow . 70 4.5 Maintenance Engineering Frameworks 70 4.6 Reliability-Centered Maintenance 72 4.7 Total Productive Maintenance . 73 4.7.1 Introduction to TPM . 73 4.7.2 The Concept of TPM 74 4.7.3 TPM Operating Instruments . 75 4.7.4 From Tradition to TPM: A Difficult Transition . 76 4.8 Maintenance Status Survey . 80 4.9 Maintenance Outsourcing and Contracts 83 5 Basic Statistics and Introduction to Reliability 87 5.1 Introduction to Reliability 88 5.2 Components and Systems in Reliability . 88 5.3 Basic Statistics in Reliability Engineering . 89 5.4 Time to Failure and Time to Repair 90 5.5 Probability Distribution Function 90 5.6 Repairable and Nonrepairable Systems . 91 5.7 The Reliability Function – R(t) 91 5.8 Hazard Rate Function 92 5.8.1 Hazard Rate Profiles . 94 5.8.2 Mean Time to Failure 95 5.9 Stochastic Repair Process . 95 5.10 Parametric Probability Density Functions . 97 5.10.1 Constant Failure Rate Model: The Exponential Distribution 97 5.10.2 Exponential Distribution. Numerical example 99 5.10.3 The Normal and Lognormal Distributions . 103 5.10.4 Normal and Lognormal Distributions. Numerical example . 106 5.10.5 The Weibull Distribution . 110 5.10.6 Weibull Distribution. Numerical Example . 112 5.11 Repairable Components/Systems: The Renewal Process and Availability A(t) 113 5.12 Applications and Case Studies . 117 5.12.1 Application 1 – Nonrepairable Components . 117 5.12.2 Application 2 – Repairable System . 122 6 Reliability Evaluation and Reliability Prediction Models . 133 6.1 Introduction 133 6.2 Data Collection and Evaluation of Reliability Parameters 134 6.2.1 Empirical Functions Direct to Data . 135 6.2.2 Theoretical Distribution Research 145 6.3 Introduction to Reliability Block Diagrams 152 6.4 Serial Configuration . 153 6.4.1 Numerical Example – Serial Configuration 154 6.5 Parallel Configuration 161xiv Contents 6.5.1 Numerical Example – Parallel Configuration . 163 6.6 Combined Series–Parallel Systems . 168 6.7 Combined Parallel–Series Systems . 170 6.8 k-out-of-n Redundancy . 170 6.8.1 Numerical Examples, k-out-of-n Redundancy 171 6.9 Simple Standby System 174 6.9.1 Numerical Example – Time-Dependent Analysis: Standby System . 180 6.10 Production System Efficiency . 183 6.10.1 Water Supplier System . 185 6.10.2 Continuous Dryer System 187 7 Maintenance Information System and Failure Rate Prediction . 189 7.1 The Role of a Maintenance Information System 189 7.2 Maintenance Information System Framework 190 7.2.1 Data Collection . 190 7.2.2 Maintenance Engineering . 192 7.2.3 Interventions and Workload Analysis . 194 7.2.4 Spare Parts and Equipment Management 195 7.3 Computer Maintenance Management Software . 196 7.4 CMMS Implementation: Procedure and Experimental Evidence 199 7.4.1 System Configuration and Integration 199 7.4.2 Training and Data Entry 200 7.4.3 Go Live . 200 7.4.4 Postimplementation Phase and Closing . 200 7.4.5 Experimental Evidence Concerning CMMS Implementation . 200 7.5 Failure Rate Prediction . 204 7.5.1 Accelerated Testing 204 7.5.2 Failure Data Prediction Using a Database . 206 7.6 Remote Maintenance/Telemaintenance . 214 7.6.1 Case Study . 216 8 Effects Analysis and Reliability Modeling of Complex Production Systems 219 8.1 Introduction to Failure Modes Analysis and Reliability Evaluation 220 8.2 Failure Modes and Effects Analysis 220 8.2.1 Product Analysis 221 8.2.2 Failure Mode, Effects, and Causes Analysis . 222 8.2.3 Risk Evaluation . 222 8.2.4 Corrective Action Planning . 225 8.2.5 FMEA Concluding Remarks 229 8.3 Failure Mode, Effects, and Criticality Analysis . 229 8.3.1 Qualitative FMECA . 231 8.3.2 Quantitative FMECA 231 8.3.3 Numerical Examples . 232 8.4 Introduction to Fault Tree Analysis . 236 8.5 Qualitative FTA . 239 8.5.1 Fault Tree Construction Guidelines . 239Contents xv 8.5.2 Numerical Example 1. Fault Tree Construction . 240 8.5.3 Boolean Algebra and Application to FTA . 241 8.5.4 Qualitative FTA: A Numerical Example . 242 8.6 Quantitative FTA 244 8.6.1 Quantitative FTA, Numerical Example 1 248 8.6.2 Quantitative FTA, Numerical Example 2 252 8.6.3 Numerical Example. Quantitative Analysis in the Presence of a Mix of Statistical Distributions 254 8.7 Application 1 – FTA . 263 8.7.1 Fault Tree Construction 264 8.7.2 Qualitative FTA and Standards-Based Reliability Prediction 266 8.7.3 Quantitative FTA 269 8.8 Application 2 – FTA in a Waste to Energy System 277 8.8.1 Introduction to Waste Treatment . 277 8.8.2 Case study . 278 8.8.3 Emissions and Externalities: Literature Review 279 8.8.4 SNCR Plant 280 8.8.5 SNCR Plant. Reliability Prediction and Evaluation Model . 281 8.8.6 Qualitative FTA Evaluation . 283 8.8.7 NOx Emissions: Quantitative FTA Evaluation 287 8.8.8 Criticality Analysis 292 8.8.9 Spare Parts Availability, What-If Analysis . 295 8.8.10 System Modifications for ENF Reduction and Effects Analysis . 300 8.9 Markov Analysis and Time-Dependent Components/Systems . 301 8.9.1 Redundant Parallel Systems . 302 8.9.2 Parallel System with Repairable Components 304 8.9.3 Standby Parallel Systems . 306 8.10 Common Mode Failures and Common Causes . 309 8.10.1 Unavailability of a System Subject to Common Causes 310 8.10.2 Numerical Example, Dependent Event 311 9 Basic Models and Methods for Maintenance of Production Systems . 313 9.1 Introduction to Analytical Models for Maintenance of Production Systems . 314 9.1.1 Inspection Versus Monitoring . 315 9.2 Maintenance Strategies . 315 9.3 Introduction to Preventive Maintenance Models 318 9.4 Component Replacement . 319 9.4.1 Time-Related Terms and Life Cycle Management 319 9.4.2 Numerical Example. Preventive Replacement and Cost Minimization . 320 9.5 Time-Based Preventive Replacement – Type I Replacement Model . 323 9.5.1 Numerical Example. Type I Replacement Model . 324 9.5.2 Numerical Example. Type I Model and Exponential Distribution of ttf . 325 9.5.3 Type I Replacement Model for Weibull distribution of ttf 326 9.5.4 The Golden Section Search Method 326xvi Contents 9.5.5 Numerical Example. Type I Model and the Golden Section Method 328 9.6 Time-Based Preventive Replacement Including Duration of Replacements 333 9.6.1 Numerical Example 1: Type I Replacement Model Including Durations T p and Tf 333 9.6.2 Type I Model with Duration of Replacement for Weibull Distribution of ttf . 335 9.6.3 Numerical Example 2: Type I Model with Durations Tp and Tf 335 9.6.4 Practical Shortcut to t p Determination 335 9.7 Block Replacement Strategy – Type II 339 9.7.1 Renewal Process 340 9.7.2 Laplace Transformation: W(t) and w(t) 341 9.7.3 Renewal Process and W(t) Determination, Numerical Example . 341 9.7.4 Numerical Example, Type II Model 343 9.7.5 Discrete Approach to W(t) 348 9.7.6 Numerical Examples . 349 9.7.7 Practical Shortcut to W(t) and t p Determination 352 9.8 Maintenance Performance Measurement in Preventive Maintenance . 353 9.8.1 Numerical Example . 354 9.9 Minimum Total Downtime 355 9.9.1 Type I – Minimum Downtime . 355 9.9.2 Type II – Downtime Minimization . 357 9.10 Group Replacement: The Lamp Replacement Problem 358 9.11 Preventive Maintenance Policies for Repairable Systems . 359 9.11.1 Type I Policy for Repairable Systems . 360 9.11.2 Type II Policy for Repairable Systems 370 9.12 Replacement of Capital Equipment . 372 9.12.1 Minimization of Total Cost . 372 9.12.2 Numerical Example . 372 9.13 Literature Discussion on Preventive Maintenance Strategies 372 9.14 Inspection Models . 373 9.15 Single Machine Inspection Model Based on a Constant Value of Conditional Probability Failure 375 9.15.1 Numerical Example 1, Elementary Inspection Model 376 9.15.2 Numerical Example 2, Elementary Inspection Model 377 9.16 Inspection Frequency Determination and Profit per Unit Time Maximization 378 9.17 Inspection Frequency Determination and Downtime Minimization . 380 9.18 Inspection Cycle Determination and Profit per Unit Time Maximization 381 9.18.1 Exponential Distribution of ttf . 381 9.18.2 Weibull Distribution of ttf 382 9.18.3 Numerical Example . 382 9.19 Single Machine Inspection Model Based on Total Cost per Unit Time Minimization 383Contents xvii 9.20 Single Machine Inspection Model Based on Minimal Repair and Cost Minimization . 384 9.21 Inspection Model Based on Expected Availability per Unit Time Maximization 385 9.22 Group of Machines Inspection Model . 386 9.23 A Note on Inspection Strategies . 387 9.24 Imperfect Maintenance . 388 9.24.1 Imperfect Preventive Maintenance p – q . 388 9.25 Maintenance-Free Operating Period 390 9.25.1 Numerical Example (Kumar et al. 1999) 391 9.25.2 MFOPS and Weibull Distribution of ttf . 392 9.26 Opportunistic Maintenance Strategy 393 10 Advanced Maintenance Modeling . 397 10.1 Introduction 397 10.2 Maintenance Policy 398 10.2.1 Age Replacement . 398 10.2.2 Block Replacement 399 10.3 Modeling of Nonrepairable Degraded Systems . 399 10.4 Modeling of Inspection-Maintenance Repairable Degraded Systems . 402 10.4.1 Calculate EŒNI . 403 10.4.2 Calculate P p 404 10.4.3 Expected Cycle Length Analysis . 405 10.4.4 Optimization of Maintenance Cost Rate Policy . 405 10.4.5 Numerical Example . 406 10.5 Warranty Concepts 406 10.6 Conclusions 408 11 Spare Parts Forecasting and Management . 409 11.1 Spare Parts Problem . 409 11.2 Spare Parts Characterization 410 11.3 Forecasting Methods . 411 11.4 Croston Model 412 11.5 Poisson Model 413 11.6 Binomial Model 414 11.6.1 Numerical Example . 415 11.7 Spare Parts Forecasting Accuracy . 416 11.8 Spare Parts Forecasting Methods: Application and Case Studies 417 11.8.1 Case Study 1: Spare Parts Forecasting for an Aircraft . 417 11.8.2 Case Study 2: Spare Parts Forecasting in a Steel Company . 418 11.9 Methods of Spare Parts Management . 422 11.9.1 Spare Parts Management: Qualitative Methods . 423 11.9.2 Spare Parts Management: Quantitative Methods 426 12 Applications and Case Studies 433 12.1 Preventive Maintenance Strategy Applied to a Waste to Energy Plant 433 12.1.1 Motor System Reliability Evaluation . 434xviii Contents 12.1.2 Bucket Reliability Evaluation . 436 12.1.3 Motor System. Determination of Maintenance Costs 437 12.1.4 Time-Based Preventive Replacement for the Motor System 439 12.1.5 Time-Based Preventive Replacement for the Bucket Component 439 12.1.6 Time-Based Preventive Replacement with Durations Tp and Tf . 441 12.1.7 Downtime Minimization . 442 12.1.8 Monte Carlo Dynamic Analysis . 442 12.1.9 Monte Carlo Analysis of the System 446 12.2 Reliability, Availability, and Maintainability Analysis in a Plastic Closures Production System for Beverages 446 12.2.1 RBD construction . 448 12.2.2 Rotating Hydraulic Machine 449 12.2.3 Data Collection and Reliability Evaluation of Components . 449 12.2.4 Reliability Evaluation, Nonrepairable Components/Systems 454 12.2.5 Data on Repairs and Maintenance Strategies . 456 12.2.6 Monte Carlo Analysis of the Repairable System 456 12.2.7 Alternative Scenarios and System Optimization 460 12.3 Conclusions and Call for New Contributions . 462 A Appendix 463 A.1 Standardized Normal Distribution 463 A.2 Control Chart Constants 464 A.3 Critical Values of Student’s Distribution with Degree of Freedom . 465 Bibliography 467 Index 475 A accelerated life testing, 204 accident, 53, 54 active maintenance time, 320 adaptive-response-rate single exponential smoothing, 412 additive Holt–Winter, 412 ADI average interdemand interval, 410, 430 Aerospace, 21 age-based replacement policy, 319 AIAG FMEA-3, 221 airlines, 6, 417 alternating renewal process, 261, 345 analytic hierarchy process, 425 Anderson–Darling, 43 ANEC, 22 ARP5580, 221 Arrhenius, 205 as bad as first failure, 124 as good as new, 96 asset management, 196 asset register, 190 associative law, 243 attribute data, 33 automation, 8 automotive, 220, 221 autonomous maintenance, 74 autoregressive integrated moving average, 412 availability, 91, 113, 127 B basic event, 237 basic statistics, 89 bathtub curve, 94 Bellcore, 213 binomial distribution, 27, 48 binomial model, 412 Birnbaum, 294 block diagram, 156 block replacement, 399 block replacement policy, 319, 339 Boolean algebra, 239, 243 breakdown, 65, 67, 236, 316 British Standards Institution, 221 BS 5760, 221 C c -chart, 39 call cost, 320 capability analysis, 25, 40 capital equipment, 372 CAPP, 12 case studies, 117 catastrophic risks, 58 causes by occurrence analysis, 227 CEN standard, 19, 21, 60 censored data, 118, 135, 145 central limit theorem, 23 check lists, 59 closure production system, 446 CM downtime, 334 CMMS, 196 Coffin–Manson model, 206 cold standby, 180 comakership with suppliers, 13 combined parallel–series system, 170 combined series–parallel system, 168 common causes, 25, 309 commutative law, 243 complete failure data, 134 component, 88 computer-aided design, 10 computer-aided manufacturing, 10 computerized maintenance management system, ix, 189 condition based maintenance, 315, 454 conditional probability, 89 conditioning event, 237 confidence interval, 137 constant failure rate, 95, 97, 247 constant interval replacement policy, 319, 339 continuous dryer system, 187 continuous improvement, 18 control charts, 25, 464 475476 Index conventional risks, 58 corrective, 67, 70 corrective actions, 227 corrective maintenance, 314 cost, 3, 203 cost control, 68 cost of emissions, 438 cost of failure, 438 cost of man work, 438 cost of materials and spare parts, 438 cost rate, 405 crew cost, 320 critical path method, 11 criticality, 294, 430 criticality matrix, 231, 234 Croston method, 412 cumulative distribution, 90 cumulative failure, 152 customer, 5, 18 CV2 squared coefficient of variation, 410, 430 cycle length, 333, 405 cycles of replacement, 369 D danger, 54 data collection, 83, 134, 191, 196 data mining, 12 data warehousing, 12 decision tree, 12 defect, 24, 50 defectives, 75 deferred maintenance, 315 degradation process, 400, 402 demand analysis, 10 density function, 90 dependent event, 311 design, 10 design FMEA (DFMEA), 220 design for assembly, 5 design for disassembly, 5 design for manufacturing, 5 design modification, 318 detection, 222, 225 DFA, 4 DFD, 5 DFM, 4 direct method, 136 discounted cash flow rate of return, 11 discrete random variable, 36 disjunction, 243 distinct causes, 240 distribution function, 36 distribution management, 13, 14 distributive law, 243 double exponential smoothing, 412 downing event criticality index, 159 downtime, 65, 115 drink vending machine, 221 duration of replacements, 336 E early wear out, 110 economic order quantity, 13 economic value added, 12 ECOS, 22 effects classification, 227 Efficiency, 183 EFTA, 19 elasticity, 3 electric power supplier, 252 electrical hazards, 55 electromigration model, 205 elementary inspection model, 376 emergency situation, 57 EN ISO 14121, 55 EN ISO 9000, 17, 19 enterprise resource program, 195 environment factor, 207 environmental standards, 21 equivalent fault tree (EFT), 244 equivalent reliability block diagram, 244 ergonomic hazards, 56 erratic demand, 411 expected cycle length, 323 expected number of failures (ENF), 113 expected overall performance, 43 expected within performance, 43 exponential distribution, 97 exponential smoothing, 10 exponential voltage model, 205 exponential weighted moving averages, 412 Eyring, 206 F failure event, 91 failure mode, 233 failure mode and effects analysis (FMEA), 222 failure mode, effects, and criticality analysis (FMECA), 220, 231 failure modes and effects analysis (FMEA), 220, 224 failure process, 90 failure rate databank (FARADA), 206 failure rate prediction, 97, 204, 211 failure replacement, 333 failure report, 191, 192 failure to danger, 57 father event, 236 fault finding, 317 fault tree analysis (FTA), 237, 239, 244, 263 FFR, 113 fire service, 60 first failure, 248 fit analysis, 118, 145 flexible automation, 9 flexible manufacturing system, 8 forecasting, 11, 410 forecasting accuracy, 416 functional scheme, 152Index 477 functional unit, 133 Fussell–Vesely, 294 G gamma function, 110 Gantt, 11 golden section search method, 326 goodness of the fit, 106, 145 Government–Industry Data Exchange Program (GIDEP), 206 great risks, 58 group replacement, 339, 358 H harm, 54 hazard, 54, 57 hazard operability, 59 hazard rate, 92, 94 head protection, 60 health, 21, 51 hearing protectors, 60 heating system, 263 hospitals, 6 hot standby, 180 I idempotent law, 243 idle time, 319 IEC 812, 221 immediate maintenance, 315 imperfect maintenance, 388, 398 improved indirect method, 136 in control, 25 incinerator, 278 independent events, 90, 239 individual censored data, 134 industrial management, 5 infant mortality, 94, 110 information technology, 8 INHIBIT gate, 237 inspection maintenance, 317, 373, 381 inspection units, 37, 38 intermediate event, 237 intermittent demand, 410, 411 International Electrotechnical Commission, 221 interval censored data, 134 inventory control, 68, 196 inverse Laplace transform, 305 inverse power rule, 205 item criticality, 232 J J1739, 220 just in time, 13 K k -out-of-n parallel, 170 Kaplan–Meier, 120, 136 key characteristic, 24 KPI, 71, 353 L lamp replacement problem, 358 Laplace transform, 302 law of absorption, 243 lean manufacturing, 73 least-square, 136, 145 left censored data, 134 life cycle management, 5, 320 life data analysis, 133 life–stress relationships, 205 linear regression, 145 location allocation problem, 13 logistic delay, 320 loglogistic function, 454 lognormal distribution, 103, 104 lower control limit, 26 lower incomplete gamma function, 324 lower specification limit, 24 lumpy demand, 411 M M –P diagram, 58 magnitude, 54, 224 maintainability, 96 maintenance, 65, 71, 398 maintenance control, 66 maintenance cost, 334 maintenance global service, 83, 215 maintenance information system, 189, 196 maintenance management, 65, 77 maintenance planning, 66 maintenance status survey, 80 maintenance strategies, 66, 315, 398, 437 maintenance-free operating period, 390 manufacturing systems, 8 market investigation, 12 market uncertainty, 2 Markov analysis, 116, 301 Martin Titan Handbook, 206 material handling device design, 11 material/substance hazards, 56 maximum likelihood estimator, 136, 149 mean absolute deviation (MAD), 416 mean absolute percentage error (MAPE), 416 mean availability, 115 mean deviation (MD), 416 mean square deviation (MSD), 416 mean time to failure (MTTF), 95, 137 mean time to repair (MTTR), 96, 429 mechanical hazards, 55 median rank, 136 memoryless, 94 micro-stops, 74 MIL-STD-1629A, 220 MIL-STD-217, 206 minimal cut sets (MCS), 239478 Index minimal repair, 371 minimum total cost method, 426 minimum total downtime, 355 mirrored blocks, 244 Monte Carlo simulation, 128, 157, 260, 275, 442 motorcycle manufacturer, 429 moving average, 10, 412 multiattribute spare tree analysis, 424 multiple censored data, 134 multiscenario analysis, 337 N net present value, 11 neural network, 145 noise hazards, 55 nonconformity, 24, 27 nonnormal probability, 46 nonparametric reliability evaluation, 101, 120 nonproduction cost, 320 nonrepairable component, 91 normal distribution, 41, 103 not conditional failure rate, 92 np-chart, 37 number of failures, 159 O occurrence–severity matrix, 227 on condition monitoring, 70 on-line counseling, 215 operating time, 319 opportunistic maintenance, 317, 393 ordinary free replacement, 407 OSHA, 53 out of control, 26 out of specification, 49 outsourcing, 83 overall equipment effectiveness OEE, 76 overhaul, 83, 316 P P-AND gate (priority AND gate), 237 p-chart, 35 parallel configuration, 161 Pareto chart, 227 part stress analysis, 207 payback analysis, 11 performance, 2 piping system, 236 planned replacement, 317 plant control, 68 plant layout, 12 PM downtime, 334 point availability, 115 Poisson distribution, 27, 38, 413 population, 23, 35 power rating factor, 207 PPM, 48 predetermined maintenance, 315 predictive maintenance, 72, 316, 439 prevention strategy, 60 preventive maintenance, 57, 314, 317, 333 pro rata warranty, 407 proactive, 72 probability distribution function, 90 probability of event, 238 probability plot, 101 process capability, 2 process design, 10 process FMEA (PFMEA), 220 product design, 10 product life cycle management, 5, 9, 320 product limit estimator method, 136 product mix, 2, 3, 5 production efficiency, 75 production planning, 14 production process, 66 production system, 2, 11, 13 production system design framework, 4 profit analysis, 12 profit per unit time maximization, 378 program evaluation and review technique, 11 project execution, 12 project planning, 11 protection, 54 protection strategy, 60 protective action, 57, 60, 63 purchase order, 196 Q quality audit, 19 quality control, 23, 68 quality factor, 207 quality management system, 18 R R -chart, 26 RADC, 212 radiation hazards, 56 radio-frequency identification, 9 RAMS, 72 random failures, 110 rank adjustment method, 136, 140 rapid wear out, 110 rate of quality, 75 RCM, 71 reactor explosion, 240 redundant system, 161, 171, 246, 302 refurbishment, 316 relevant accident, 58 reliability, 88 reliability based preventive maintenance, 316 reliability block diagram, 152 reliability database, 267 reliability function, 91 reliability libraries, 268 reliability of system, 153, 163, 434 reliability parameters evaluation, 133, 454Index 479 remote maintenance, 190, 214 renewal process, 113, 115, 340 repair process, 91, 95, 99, 248 repair time, 320 replacement, 317 replacement upon failure, 317 required time, 319 research for productivity, 2 residual risk, 59 restoration, 316, 346 right censored data, 134 risk, 53, 56 risk analysis, 54, 57, 222 risk priority number (RPN), 220 Rome Air Development Center (RADC), 206 running in period, 94 S s -chart, 30 SABE, 21 safety, 53 safety of machinery, 61 safety stock, 13 scheduled-basis preventive maintenance, 316 scheduling, 10 sequencing, 10 serial configuration, 153 service life period, 94 severity, 222, 232 shock damage, 400 simple standby system, 174 simulation, 11, 157 single exponential smoothing, 412 Six Sigma analysis, 48 six-pack capability analysis, 43 spare parts, 195, 295, 320, 409 spare parts forecasting, 411, 414 spare parts management, 7, 423, 426 specific/minor risks, 58 specification limit, 24 stakeholders, 4 standardized MAD (SMAD), 416 standardized normal distribution, 463 standby system, 180, 246, 319 state diagram, 157 static reliability importance analysis, 252 statistical quality control, 24 steady-state availability, 115 stochastic failure and repair process, 89, 95, 117 storage cost, 409 stress factor, 207 student distribution, 137, 465 successful configuration, 171 supply plant, 152 survival function, 92 switching device, 180 T Telcordia, 213 telemaintenance, 214 thermal hazards, 55 thermal water treatments, 51 three stress models, 206 time series, 10, 59 time series decomposition, 412 time to failure, 90 time to market, 3 time to repair, 90 time-based preventive maintenance, 316 time-dependent analysis, 180, 301 top event, 237, 239 top-down analysis, 233 total expected replacement cost per cycle, 323 TPM, 71, 73, 76 transfer out block, 265 transporation, 13 traveling scheduling procedures, 11 two temperature/voltage models, 205 two-state diagram, 91 type I model, 324, 328 type II model, 319, 343, 357 U unavailability, 247 UNI, 19 unlimited free replacement, 407 up/down analysis, 132, 157 uptime, 65 use-based preventive maintenance, 316 V variety reduction program, 7, 12 VED approach, 423 vehicle routing, 12, 13 Venn diagrams, 241 vibration hazards, 55 VRP, 7, 12 W warm standby, 307 warranty, 406, 407 waste to energy plant, 433 waste treatment, 277 water supplier system, 185 wear out, 94 Weibull distribution, 47, 110, 454 weighted moving averages, 412 what-if analysis, 12 wood panel manufacturing, 216 work order, 191 X Nx -chart, 29
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