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 |  موضوع: كتاب Rules of Thumb for Maintenance and Reliability Engineers الأحد 02 يونيو 2024, 12:25 pm | |
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أخواني في الله
أحضرت لكم كتاب
Rules of Thumb for Maintenance and Reliability Engineers
Ricky Smith and R. Keith Mobley
و المحتوى كما يلي :
Contents
Introduction—The Recommended First
Step to Rules of Thumb in Reliability
Engineering xiii
P A R T
I
THE BASICS OF MAINTENANCE
AND RELIABILITY
C H A P T E R
1
Understanding Maintenance
and Reliability
1.1. The Maintenance Function 3
1.2. Strategy to Achieve World-Class
Production through Reliability 3
1.2.1. Maintenance Approaches 4
1.2.2. Maintenance Management
Philosophy 4
1.2.3. The Function and Control System 5
1.2.4. What Is Maintenance? 5
1.2.5. Specification 6
1.2.6. The Maintenance Function 6
1.3. What Is Reliability? 8
1.3.1. Companies That Get It 8
1.3.2. Why Move Toward Proactive Work? 9
1.3.3. A New Way to View Failure 10
1.4. Maintenance/Reliability Assessment 10
1.5. Introduction to Change Management 14
1.6. Developing a Business Case for
a Reliability Initiative 16
1.7. Calculating Return on Investment 19
1.7.1. Leadership of the ROI Team 19
1.7.2. Case Study 19
1.8. Planning and Scheduling 21
C H A P T E R
2
The Functional Maintenance
Organization and Its People
2.1. Functional Maintenance Organizational
Structure 27
2.2. Maintenance Supervisor 29
2.2.1. Responsibilities 29
2.2.2. Environmental, Health, and
Safety Aspects 30
2.3. Maintenance Planner/Scheduler 30
2.3.1. Responsibilities 30
2.4. Maintenance and Engineering Manager 31
2.4.1. Responsibilities 31
2.4.2. Environmental, Health, and
Safety Aspects 32
2.5. Area Manager of Warehouse and
Inventory Control 32
2.5.1. Responsibilities 32
2.6. Reliability Engineer 33
2.6.1. Responsibilities 34
2.6.2. Job Skills 34
2.6.3. Reliability Engineering Dashboard—Key
Performance Indicators 35C H A P T E R
3
Preventive Maintenance Program
3.1. Reliability-Based Preventive
Maintenance 37
3.1.1. Information Collection 38
3.1.2. System Analysis 38
3.1.3. Identification of Systems 38
3.1.4. Identification of System
Functions 38
3.1.5. Selection of Systems 38
3.1.6. System Functional Failure and
Criticality Rating 40
3.2. Identification of Functionally
Significant Items 40
3.3. Maintenance Task Selection (Decision Logic
Tree Analysis) 40
3.3.1. Levels of Analysis 41
3.3.2. Paralleling and Default Logic 43
3.4. Maintenance Tasks 43
3.5. Task Frequencies/Intervals 44
C H A P T E R
4
Predictive Maintenance Program
4.1. Setting Up a Preventive/Predictive
Maintenance Program 49
4.2. Visual Inspection 50
4.3. Vibration Analysis 50
4.4. Thermography 53
4.5. Tribology 54
4.6. Ultrasonics 56
C H A P T E R
5
Reliability Processes
5.1. Reliability Software—Managing the
Health of Assets 57
5.1.1. Building an Effective Asset
Reliability Program 58
5.1.2. Using Reliability Software to Put
the Program into Action 58
5.1.3. Using Handheld Devices to Collect
and Upload Condition Inspection Data 59
5.1.4. Plotting Asset Health Trends 61
5.1.5. Capturing the Experts’ Knowledge
about Asset Condition 61
5.1.6. Integration to Enterprise Asset
Management and Computerized
Maintenance Management Systems 62
5.1.7. The Bottom Line 63
5.2. Seven Questions Addressed by Reliability
Centered Maintenance 63
5.3. Failure Mode and Effects Analysis 66
5.4. Equipment Criticality Analysis 68
5.4.1. Preparing for an Equipment
Criticality Analysis 71
5.4.2. Conducting the Review 72
5.4.3. Analyzing the Assessment Results 75
5.4.4. Using the Output of the Equipment
Criticality Assessment 77
5.4.5. Conclusions 78
5.5. Root Cause Analysis 79
5.5.1. Plan 79
5.5.2. Do 81
5.5.3. Check 83
5.5.4. Act 86
C H A P T E R
6
Key Performance Indicators
6.1. Defining and Understanding KPIs 89
6.1.1. The Problem 90
6.1.2. John Day 91
6.1.3. The Solution 93
6.2. KPI Dashboards 93
6.2.1. Plant Manager Dashboard 93
6.2.2. Plant Management Team Dashboard 93
6.2.3. Production Manager (Supervisor)
Dashboard 94
6.2.4. Production Operator Dashboard 94
6.2.5. Maintenance Manager (Supervisor)
Dashboard 94
6.2.6. Maintenance Staff Dashboard 95
6.2.7. Reliability Engineer Dashboard 95
6.2.8. Engineering Manager Dashboard 95
6.2.9. Purchasing Manager Dashboard 95
6.2.10. Maintenance Stores Manager 95
6.2.11. Conclusion 95
viii Contents6.3. Measuring and Managing the
Maintenance Function 95
6.3.1. Physical Asset Management 96
6.3.2. The Asset Reliability Process 97
6.3.3. Performance Metrics for the
Maintenance Function 99
6.3.4. Reliability Process Key Performance
Indicators—Leading Measures 99
6.3.5. Work Identification 99
6.3.6. Work Planning 100
6.3.7. Work Scheduling 100
6.3.8. Work Execution 101
6.3.9. Follow-Up 101
6.3.10. Performance Analysis 101
6.3.11. Key Performance Indicators of
Maintenance Effectiveness
(Result Measures) 102
6.3.12. The Importance of the Work
Order 103
6.3.13. Reporting and Use of Key
Performance Indicators 103
6.3.14. Conclusion 104
C H A P T E R
7
Total Productive Maintenance
7.1. Introduction to Total Productive
Maintenance 107
7.1.1. The TPM Organization 107
7.1.2. TPM Objectives 108
7.1.3. Autonomous Maintenance 108
7.1.4. Equipment Management 108
7.1.5. TPM Integration 108
7.1.6. TPM Is an Investment 108
7.1.7. Calculating Major Losses Is Key
to TPM’s Success 109
7.2. Lean Reliability 111
7.2.1. The Evolution from Lean
Manufacturing to Lean Maintenance
to Lean Reliability 111
7.2.2. Managing Asset P erformance
to Meet Customer Needs 112
7.2.3. The Basic Principles of Lean
Reliability 114
7.2.4. How Lean Reliability Aligns
with TPM, Kaizen, Five S,
and Six Sigma 117
7.2.5. Key Elements to Implement and
Sustain Lean Reliability 119
7.2.6. Summary 120
P A R T
II
EQUIPMENT AND PROCESSES
C H A P T E R
8
Chain Drives
8.1. Chain Selection 124
8.1.1. Plain or Detachable-Link Chain 124
8.1.2. Roller Chain 124
8.1.3. Sprockets 124
8.2. Chain Installation 124
8.3. Power Train Formulas 125
8.3.1. Shaft Speed 125
8.4. Chain Length 126
8.5. Multiple Sprockets 126
8.6. Chain Speed 127
8.7. Preventive Maintenance Procedures 127
C H A P T E R
9
Hydraulics
9.1. Hydraulic Knowledge 129
9.2. Hydraulic Troubleshooter 129
9.3. General Maintenance Person 129
9.4. Best Maintenance Hydraulic
Repair Practices 130
9.5. Root Cause Failure Analysis 130
9.6. Preventive Maintenance 130
9.7. Measuring Success 132
9.8. Recommended Maintenance Modifications 133
C H A P T E R
10
Maintenance Welding
10.1. Shielded Metal Arc Welding (SMAW), “Stick
Welding” 136
10.2. Flux-Cored Arc Welding (FCAW) 137
10.2.1. FCAW with Gas 137
10.2.2. FCAW Self-Shielded 137
10.3. Gas-Shielded Metal Arc Welding (GMAW) 141
Contents ix10.3.1. GMAW for Maintenance Welding 141
10.3.2. Gas Selection for GMAW 141
10.4. Gas Tungsten Arc Welding (GTAW) 144
10.4.1. Applicability of GTAW 145
10.4.2. Advantages and Disadvantages
of GTAW 145
10.4.3. Principles of Operating GTAW 145
10.4.4. Polarity and GTAW 147
10.4.5. GTAW Shielding Gases and Flow
Rates 147
10.4.6. Electrode Material for GTAW 148
10.4.7. GTAW Electrode Size and Tip
Shape 148
10.4.8. GTAW Electrode Holders and Gas
Nozzles 149
10.4.9. Characteristics of GTAW Power
Supplies 149
10.4.10. GTAW Torches 150
10.4.11. Manual GTAW Techniques 151
10.4.12. Establishing Welding Parameters
for GTAW 151
10.4.13. Gas Tungsten Arc Starting
Methods 151
10.5. Oxyacetylene Cutting 151
10.6. Air-Carbon Arc Cutting and Gouging 152
10.6.1. Applications 153
10.6.2. Power Sources 154
10.7. Plasma Arc Cutting 155
10.8. Welding Procedures 157
10.9. Qualification of Welders 157
10.10. Plasma Arc Welding 157
10.11. Base Metals 157
10.11.1. The Carbon Steels 157
10.11.2. The Alloy Steels 158
10.11.3. The Nonferrous Metals 160
10.12. Control of Distortion 160
10.13. Special Applications 161
10.13.1. Sheet Metal Welding 161
10.13.2. Hard Surfacing 161
10.13.3. Resisting Abrasive Wear 161
10.13.4. Resisting Impact Wear 161
10.13.5. Types of Surfacing Electrodes 163
10.13.6. Choosing Hard-Facing Material 163
10.13.7. Check Welding Procedure 165
10.13.8. Check Before the Part Is
Completely Worn 165
10.13.9. Hard Surfacing with SAW 165
10.14. Selection and Maintenance of Equipment 167
10.14.1. Machines 167
10.14.2. Accessory Equipment 169
10.15. Installation of Equipment 169
10.16. Equipment Operation and Maintenance 170
10.16.1. Keep the Machine Clean and Cool 170
10.16.2. Do Not Abuse the Machine 170
10.16.3. Do Not Work the Machine
Over Its Rated Capacity 170
10.16.4. Do Not Handle Roughly 170
10.16.5. Maintain the Machine
Regularly 170
10.17. Safety 172
C H A P T E R
11
Bearings
11.1. Types of Movement 175
11.1.1. About a Point (Rotational) 175
11.1.2. About a Line (Rotational) 175
11.1.3. Along a Line (Translational) 175
11.1.4. In a Plane (Rotational/
Translational) 178
11.2. Commonly Used Bearing Types 178
11.2.1. Plain Bearings 178
11.2.2. Rolling Element or Antifriction 182
11.2.3. Roller 185
11.3. Bearing Materials 187
11.3.1. Plain 188
11.3.2. Rolling Element 188
11.4. Lubrication 188
11.4.1. Plain Bearings 188
11.4.2. Rolling Element Bearings 189
11.5. Installation and General Handling
Precautions 190
11.5.1. Plain Bearing Installation 190
11.5.2. Roller Bearing Installation 190
11.5.3. General Roller-Element Bearing
Handling Precautions 192
11.6. Bearing Failures, Deficiencies, and
Their Causes 193
11.6.1. Improper Bearing Selection and/or
Installation 193
C H A P T E R
12
Compressors
12.1. Centrifugal 199
12.1.1. Configuration 199
12.2. Performance 201
12.2.1. First Law of Thermodynamics 201
12.2.2. Second Law of Thermodynamics 202
12.2.3. Pressure/Volume/Temperature
(PVT) Relationship 202
x Contents12.2.4. Pressure/Compression 202
12.2.5. Other Performance Indicators 202
12.3. Positive Displacement 203
12.3.1. Rotary 203
12.4. Reciprocating 206
12.4.1. Configuration 207
12.4.2. Performance 210
12.4.3. Installation 210
12.4.4. Operating Methods 212
12.5. Troubleshooting 212
12.5.1. Centrifugal 212
12.5.2. Rotary-Type, Positive Displacement 212
12.5.3. Reciprocating, Positive
Displacement 216
C H A P T E R
13
Gears and Gearboxes
13.1. Spur Gears 225
13.2. Pitch Diameter and Center Distance 226
13.3. Circular Pitch 227
13.4. Diametrical Pitch and Measurement 227
13.4.1. Method 1 228
13.4.2. Method 2 228
13.5. Pitch Calculations 228
13.6. Tooth Proportions 229
13.7. Backlash 230
13.8. Other Gear Types 230
13.8.1. Bevel and Miter 230
13.8.2. Helical 231
13.8.3. Worm 232
13.8.4. Herringbone 233
13.8.5. Gear Dynamics and Failure Modes 233
13.8.6. Common Characteristics 235
13.9. Troubleshooting 236
13.9.1. Normal Wear 237
13.9.2. Abnormal Wear 237
C H A P T E R
14
Packing and Seals
14.1. Fundamentals 239
14.1.1. Shaft Seal Requirements 239
14.1.2. Sealing Devices 239
14.2. Mechanical Seal Designs 242
14.2.1. Single-Coil Spring Seal 242
14.2.2. Positive Drive 242
14.3. Installation Procedures 242
14.3.1. Packed Stuffing Box 243
14.3.2. Mechanical Seals 245
14.4. Troubleshooting 248
14.4.1. Mechanical Seals 248
14.4.2. Packed Boxes 249
C H A P T E R
15
Electric Motors
15.1. Bearing Frequencies 251
15.2. Imbalance 251
15.3. Line Frequency 251
15.4. Loose Rotor Bars 251
15.5. Running Speed 252
15.6. Slip Frequency 252
15.7. V-Belt Intermediate Drives 252
15.8. Electric Motor Analysis 252
P A R T
III
ADDITIONAL READINGS ON
MAINTENANCE AND
RELIABILITY
C H A P T E R
16
Reliability Articles
16.1. Top Five Reasons Why Companies Don’t
Measure Reliability: It Seems Like Everyone
Has an Excuse as to Why They Don’t Measure
Reliability 255
16.1.1. Reason 1 255
16.1.2. Reason 2 255
16.1.3. Reason 3 255
16.1.4. Reason 4 255
16.1.5. Reason 5 256
16.2. Creating a Culture Change in Your Maintenance
Department: Is Your Maintenance Crew in a
Reactive Mindset? Check Out a List of Qualifiers
to Find Out and Then Learn How to Change
It 256
Contents xi16.3. Exterminate Lube Problems: Grease and
Oil Expertise Can Be a Serious Competitive
Edge 257
16.3.1. Big, Bad, and Ugly 257
16.3.2. Make Lube Expertise a Specialty 258
16.3.3. Get the Job Done 260
16.4. What It Takes to Make the Climb from
Reactive to RCM 260
16.4.1. Waving the Flag 261
16.4.2. Does Management Understand? 269
16.4.3. Who Owns Reliability? 270
16.4.4. Informal versus Formal PM
Programs 270
16.4.5. To Measure Is to Manage 270
16.4.6. Depth of Understanding 271
16.4.7. Indicated Actions 272
16.4.8. Lessons Are Simple 273
16.5. Put a Plant-wide Focus on Functional
Failures 274
16.6. Reliability Is Worth a Second Look: Statistical
Analysis and Time-Based Preventive
Maintenance Don’t Really Address the Ability
to Perform—It’s Time to Get Familiar with the
Definition of Reliability 275
16.7. When Preventive Maintenance Doesn’t
Work 276
16.8. The Top Four Reasons Why Predictive
Maintenance Fails and “What to Do about It” 277
16.8.1. PF Curve 278
16.8.2. Reason 1: The Collection of PdM Data
Is Not Viewed as Part of the Total
Maintenance Process 278
16.8.3. Reason 2: The Collected PdM Data
Arrives Too Late to Prevent Equipment
Failures 279
16.8.4. Reason 3: Many Companies Fail to Take
Advantage of Data from PLCs and
DCSs 279
16.8.5. Reason 4: Most PdM Data Is Dispersed
in Too Many Non-Integrated
Databases 280
16.8.6. Some Simple Guidelines Will Help to Get
You Moving in the Right Direction 281
16.8.7. Summary 282
C H A P T E R
17
MTBF Users Guide
17.1. Understanding Definitions 283
17.2. The MTBF Process 283
17.3. Example 284
17.3.1. MTBF Percentage Change 284
17.3.2. Total Plant MTBF 284
17.4. Summary 284
A P P E N D I X
A
Workflow for Planning
A P P E N D I X
B
Checklists and Forms
Glossary 315
Index 319
Index
A
Assessment,
Culture Change, 256
Maintenance and Reliability, 11–14
Asset Reliability, 256, 257
Asset Reliability Process, 14, 68, 69,
97–99, 104, 271, 273, 274, 282
Autonomous Maintenance, 108, 117
B
Bad Actors, 12, 13, 35, 95, 255, 266, 276
Bearing Selection Guide, 176–181
Bearing Survey Results, 257–259
Bearing Troubleshooting, 193, 194
Bearings, 175–197
Benchmarks,
KPIs, 92, 93, 106
World Class, 8, 9, 90, 91, 93, 95, 99,
100, 101, 103, 105, 270
Business Case, 11, 18–20, 34, 69, 77, 78,
93, 119, 256, 273
C
CMMS (Computerized Maintenance
Management System), 10, 12, 13,
18, 29, 30, 58, 59, 62, 63
CMMS Problems, 255, 271, 279
Case Study,
Maintenance and Reliability, 20,
270
Chain Drive PM Procedures, 127
Chain Drives, 113–127
Change Management, 14–18
Churchill, Winston, 271
Compressor, 199–223
Compressor Troubleshooting, 212
Condition Monitoring, 57–59, 61, 65,
260, 271
Culture Change, 14–18, 108–119, 256
D
Dashboard,
KPI, 93
Data Collection, 63
Deming, W. Edward, 270
E
Education and Training, 28–34, 258,
259
Electric Motor, 251, 252
Emergency Work Order, 5
Enterprise Asset Management
Software (EAM), See “CMMS”
Equipment Criticality Analysis, 68–76
F
FMEA (Failure Modes Effect Analysis),
11, 12, 34, 40, 66–68, 268, 270, 274,
275
Failure Effects, 40, 64, 68
Failure Modes, 34, 40, 57–59, 61–67,
116–118, 265, 270, 272, 277–279,
281
Functional Failure(s), 37–41, 63, 64,
114, 115, 265, 266, 271, 274
G
Gear Backlash, 230, 235, 237
Gear Failure Modes, 237, 259
Gear Troubleshooting, 236
Gears, 225–238, 258, 259
H
Hidden Plant, 11
Hydraulic PM Procedure, 132
Hydraulics, 129, 131, 133
Best Practices, 131
I
Indicators, See “KPIs”
K
KPI Dashboards, 35, 93–95
KPIs, 95
Leading and Lagging, See “Leading
and Lagging Indicators”
Maintenance Effectiveness, 101, 102
Kaizen (5s), 117, 118
Key Performance Indicator
Dashboard,
Reliability Engineer, 35, 95
Key Performance Indicators, 11, 13, 19,
35, 89–106, 262, 269, 270
L
Leading and Lagging Indicators, 3, 11,
13, 14, 104–106
Lean Reliability, 117–120
Lubrication Failure, 259
Lubrication Problems, 256–260
Lubrication Survey Results, 257–260
M
MTBF, 283
Maintenance,
Reactive Model, 4
Maintenance and Engineering
Manager Responsibilities, 31, 32
Maintenance and Reliability
Assessment, 4, 11, 14
Maintenance Approaches, 4
Maintenance Effectiveness Measures,
80, 101, 102
Maintenance (Reliability) Engineer
Responsibilities, 33–35
Maintenance Function, 3–6, 8, 29320 Index
Maintenance Organizational Structure,
28, 29, 31, 33, 35
Maintenance Planner/Scheduler
Responsibilities, 30, 31
Maintenance Supervisor
Responsibilities, 29, 30
Maintenance Task, 37–44
Maintenance Task Selection Criteria,
37–39
Maintenance Warehouse Supervisor
Responsibilities, 32, 33
Major Losses,
Calculation, 109, 110, 113, 117
Mean Time between Failure
(MTBF), 35, 94, 95, 104, 255, 262,
283, 284
Example, 284
Users Guide, 283, 284
Motors,
Electric, 251, 252
N
Nicholas, Jack,
Reliability Expert, 269
O
O’Hanlon, Terrence,
Reliability Expert, 271
Organizational Structure, 27–28
P
P-F Interval, 10, 115
PF Curve, 10, 278, 279
PF Curve Model, 10
Packing and Seals, 239–250
Performance Analysis, 63, 69
Performance Breakthrough, 272, 273
Physical Asset Management, 70, 78
Planning and Scheduling
Maintenance, 4, 5, 8, 21, 77, 100,
89, 91, 98–105
Planning and Scheduling Work Flow
Process, 22
Predictive Maintenance, 8, 11, 16,
47–56, 59, 77
Thermography, 47, 48, 53, 54
Tribology, 47, 48, 54–56
Ultrasonics, 48, 56
Vibration Analysis, 48–56
Predictive Maintenance Monitoring
Techniques Table, 48
Predictive Maintenance Problems,
277–282
Proactive Asset Reliability Model, 68,
69, 97, 98, 273
Preventive Maintenance, 37–44, 57, 72,
107, 114, 115, 260, 264
Preventive Maintenance Problems, 10,
11, 15, 24, 57, 72, 115, 275
Proactive Work, 9, 57, 58, 99, 100,
102–104, 106
R
RCM (Reliability Centered
Maintenance), 9, 57, 58, 63, 77, 275
ROI (Return on Investment), 20, 21,
256, 269
Reliability, 3
Calculating Return on Investment,
20
Case Study, 20
Reliability Decision Logic Tree, 41, 42
Reliability Engineering, 12, 28, 33–35,
66, 79, 95, 104
Reliability Software, 57–63, 116, 279,
282
Reliability Survey, 260–269
Roller Chain, 124
Root Cause Failure Analysis, 79, 130
Run to Failure, 58, 59, 65, 66
S
Seals,
Failure Modes, 248, 249
Mechanical, 239–249
Six Sigma, 117–119
Software,
Reliability Monitoring, 57–63, 116,
279, 282
T
TPM,
11 Major Losses, 109
Total Equipment Failure, 283, 284
Total Productive Maintenance
(TPM), 107, 109, 111, 113, 115,
117, 119
Training and Education, 6, 8, 14, 16, 20,
21, 28–34
W
Welding,
Maintenance, 135–174
Welding Electrodes, 156–169
Work Execution, 69
Work Follow-up, 61, 69
Work Planning, 62, 69, 77
World Class Maintenance, 8, 9, 14, 90,
91, 93, 95, 99–101, 103, 105
World Class Production, 39
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