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Productivity and Reliability-Based Maintenance Management
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by: Matthew P. Stephens, Ph.D., Purdue University
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Description
For courses in Quality Control and Maintenance Management taught in departments of Mechanical, Industrial, Manufacturing or Engineering Technology.
This text provides a strong, yet practical, foundation in and understanding of the concepts and practices of Total Productive Maintenance (TPM) Management, a proactive asset and resource management strategy that is based on enhancing equipment reliability and overall enterprise productivity. This educational and practical guide stresses the departure from the wait-failure-emergency repair cycle that has plagued too many industries; instead, it emphasizes the fundamentals of a proactive and productive maintenance strategyavert failure by avoiding it first. Relevant and real-world case studies used in every chapter focus on the importance of sound maintenance practices; and problems and discussion questions summarize and solidify concepts.
About the Author(s)
Matthew P. Stephens is a professor and a University Faculty Scholar in the Department of Industrial Technology at Purdue University, where he teaches graduate and undergraduate courses in total productive maintenance management (TPM), facilities planning, and statistical quality control. Professor Stephens holds undergraduate and graduate degrees from Southern Illinois University and the University of Arkansas, with specialization in operations management and statistics.
Prior to joining academe, Dr. Stephens spent nine years with several manufacturing and business enterprises, including flatbed trailer and washer and dryer manufacturers. He also has been extensively involved as a consultant with a number of major manufacturing companies.
Professor Stephens has numerous publications to his credit in the areas of productivity and quality improvements and lean production systems. He is the coauthor of Manufacturing Facilities Design and Material Handling, 2nd ed. (Prentice Hall, 2000). He has served various professional organizations including the National Association of Industrial Technology and the American Society for Quality, of which he is a Senior Member and a Certified Quality Engineer.
Table of Contents
1. Introduction.
2. Statistical Applications.
3. Preventive Maintenance.
4. Predictive Maintenance.
5. Nondestructive Testing and Evaluation.
6. Implementing TPM.
7. TPM Implementation and Process Improvement Tools.
8. Facility Maintenance Projects Planning and Control.
9. Computerized Maintenance Management Systems.
Solutions and Answers to Selected Questions.
Index.
Features
* Proactive approach to maintenance practicesStresses the importance of TPM Management, which increases productivity and quality, reducing failure and downtime.
Prepares students for their future careers with a world-class maintenance approach.
* Emphasis on reliability and expected failureUtilizes this knowledge to schedule maintenance activities at the most convenient times.
Enables students to understand this concept and apply it to both competitive manufacturing and industrial environments.
* Detailed treatment of operator preventive and predictive maintenance practice and strategy.
Teaches students the importance of operator education, involvement, and ownership in managing enterprise assets.
* Emphasis on preventionUses powerful yet easy-to-use techniques such as fault tree, cause and effect, and failure mode and effect analysis (FMEA).
Shows students that if they learn these problem-solving and productivity improvement techniques they will be marketable and sought-after upon graduation, as these concepts can be applied to all industrial and service enterprises.
* Extensive pedagogyProvides examples, discussion questions, and end-of-chapter problems.
Helps students understand the mathematical as well as conceptual problems. Provides instructors with clear and relevant examples that aid in course instruction.
* Case in Point featureUsed in every chapter; these relevant and real-world case studies solidify the concepts presented.
Highlights for students the importance of sound and proactive maintenance practices and puts these concepts in context.
* Enjoyable, readable presentationPreserves the subject matter through simplicity.
Encourages students by providing a format that is simple, yet comprehensive, enabling them to easily master the material.
Preface
Productivity and Reliability-Based Maintenance Management is intended to provide a strong yet practical foundation for understanding the concepts and practices of total productive maintenance (TPM) managementa proactive asset and resource management strategy that is based on enhancing equipment reliability and overall enterprise productivity. The book is intended to serve as a fundamental yet comprehensive educational and practical guide for departing from the wait-failure-emergency repair cycle that has plagued too many industries and advancing to a proactive and productive maintenance strategy. It is not intended to be a how-to-fix-it manual but instead emphasizes the concept of a world-class maintenance management philosophy to avoid the failure in the first place.
This book serves to fill an immense void in the instructional needs of technology students at all levels. Universities, junior and community colleges, and technical institutes as well as professional, corporate, and industrial training programs can benefit by incorporating these fundamental concepts in their technical and managerial curricula. It can serve as a powerful educational tool for students as well as for maintenance professionals and managers.
In Chapter 1, various types of maintenance organizations and practices are defined and discussed. Through a realistic cost-and-benefit approach, the book introduces the reader to the basic concepts of productivity through proactive maintenance management practices.
The introductory chapter is followed by a discussion of equipment life expectancy, expected failure rates, and the general concepts of reliability in Chapter 2. Basic statistical models and distributions necessary for understanding reliability issues also are discussed. The author embraces the philosophy that concepts, simple or complex, are best appreciated by the reader when they are presented in a clear and easy-to-understand manner. Therefore, all mathematical presentations are reduced to the simplest form.
Chapters 3 and 4 provide a clear presentation of state-of-the-art yet practical preventive and predictive techniques and applications, followed by an in-depth discussion of nondestructive testing and evaluation techniques as they are applicable to maintenance management strategies in Chapter 5. Practical steps for determining current equipment effectiveness and real-world guidelines and examples for implementation of TPM are presented in Chapters 6 and 7. Strong emphasis is placed on operator and employee education, empowerment, and ownership of equipment and processes.
Other important and relevant failure prevention and productivity improvement topics such as benchmarking; cause and effect, root cause analysis; fault tree; and failure mode and effect analysis (FMEA) are presented in Chapter 7. Clear emphasis is placed on the applicability of these tools in the maintenance arena. Chapter 8 takes a practical look at maintenance project management, and the application of various tools is explained. CMMS (computer maintenance management systems) and its role in modern maintenance management are introduced in Chapter 9.
Relevant and real-world case studies are used in most chapters in the Case in Point features, in order to highlight the importance of sound and proactive maintenance practices. End-of-chapter questions summarize and solidify the concepts that are presented in each chapter.
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