Complete Project Manager’s Toolkit

Maintenance Systems and Documentation......Page 4
Contents......Page 6
Preface......Page 12
Acknowledgments......Page 14
Author\'s biography......Page 16
Part 1 Introductory chapters......Page 18
1 A business-centered approach to maintenance systems......Page 20
1.2 Business-centered maintenance......Page 21
1.3 An example of the application of BCM: background......Page 23
1.4 Part A: Audit of the FPP maintenance department......Page 24
1.4.1 Maintenance objectives......Page 25
1.4.2 Life plans and preventive schedule......Page 26
1.4.3 Workload......Page 28
Resource structure......Page 29
Administrative structure......Page 32
1.4.5 Maintenance work planning......Page 33
1.4.6 Maintenance control system......Page 36
Maintenance effectiveness......Page 38
1.4.7 Maintenance documentation......Page 40
1.5 Part B: An alternative maintenance strategy for continuous operation......Page 42
1.6 Part C: A longer-term view of organizational change......Page 43
1.7 The strategic thought process......Page 44
References......Page 45
2 Introduction to maintenance management systems......Page 50
2.1 The company expressed as a hierarchic systems model......Page 51
2.2 Identifying the maintenance systems......Page 53
References......Page 54
Part 2 Budgeting and control......Page 56
3 Maintenance budgeting......Page 58
3.2 Maintenance budgeting......Page 59
3.3 The budgeting procedure......Page 62
4 Maintenance management control......Page 70
4.1 Introduction......Page 71
4.2 The basics of maintenance management control......Page 72
4.3 Principles of maintenance management control......Page 73
4.4 The control of overall maintenance performance......Page 74
4.5.1 Reactive control of plant reliability......Page 78
4.5.2 Pro-active control of unit reliability......Page 79
4.6 The control of organizational efficiency......Page 80
4.7 Incorporating systems into the organization......Page 81
4.10 Human factors and data collection......Page 84
References......Page 86
Part 3 Work planning and work control......Page 88
5 Short-term work planning and control......Page 90
5.2 The fundamentals of work planning......Page 91
5.3 Modeling the operation of a short-term work planning system......Page 92
5.3.1 The shift work planning system......Page 96
5.3.2 The weekend work planning system......Page 98
5.3.3 Feedback of maintenance data for control......Page 99
5.4 Comments on work planning and work control......Page 100
5.5 Guidelines for the design of work planning systems......Page 101
5.6 Safety aspects......Page 105
6 Management of plant turnarounds – Part 1: Network analysis......Page 108
6.1 Introduction......Page 109
6.2 Terms, concepts and definitions in network analysis......Page 110
6.3 The network planning procedure......Page 113
6.3.2 Constructing the logic diagram......Page 114
6.3.3 Establishing the critical path, floats and overhaul time......Page 116
6.3.4 Deriving a bar chart from the network......Page 118
6.3.5 Resource histograms......Page 119
6.4 Comments......Page 120
7 Management of plant turnarounds – Part 2: Turnaround methodology......Page 126
7.2.1 Forming a policy team and appointing a turnaround manager......Page 127
7.2.2 Key policy decisions for the initiation phase......Page 130
7.3.1 Analyzing and validating the workscope......Page 131
7.3.4 Identifying pre-shutdown work......Page 133
7.3.7 Techniques for creating a schedule......Page 137
7.3.9 Forming the turnaround organization......Page 140
7.3.11 Formulating a cost estimate......Page 142
7.3.12 Formulating a safety plan......Page 143
7.3.14 Briefing of all turnaround personnel......Page 144
7.4.1 The shutdown of the plant......Page 145
7.4.5 Monitoring progress, productivity, safety, quality and expenditure......Page 146
7.5 Phase 4: Terminating the turnaround......Page 147
Part 4 Spare parts management......Page 152
8 Spare parts management......Page 154
8.1 Introduction......Page 155
8.2 Outline of the stores operation......Page 156
8.3.1 Inventory policy for fast-moving spares......Page 159
8.3.2 Inventory policies for the control of slow-moving spares......Page 162
8.4.2 The rotable system......Page 167
8.4.3 Rotable inventory policy: the theory......Page 170
8.5 Inventory policy guidelines......Page 172
8.6 Stores documentation......Page 173
8.7 Stores organization......Page 177
8.8 Stores and rotable performance indices......Page 178
8.9 Summary......Page 179
References......Page 180
Part 5 Documentation......Page 182
9 Maintenance documentation systems: what they are and how they work......Page 184
9.2 A functional model......Page 185
9.3 Plant inventory (Module 1)......Page 187
9.4 Information base (Element 2)......Page 189
9.5 Preventive maintenance schedule (Module 3)......Page 194
9.6 Condition monitoring (Module 4)......Page 196
9.7 Short-term work planning (Module 5)......Page 197
9.8 Long-term work planning (Module 6)......Page 199
9.9 Maintenance control (Module 7)......Page 202
9.10 Summary......Page 204
Reference......Page 205
10 Computerized maintenance information systems: their uses and problems......Page 206
10.2 Computerized documentation: historical background......Page 207
10.3 The benefits of computerized maintenance information systems......Page 210
10.4 The problems with computerized maintenance information systems......Page 212
10.5 Summary......Page 213
References......Page 214
Part 6 Case study......Page 216
11 Case study: Maintenance audit of an agricultural chemical plant......Page 218
11.2 An overview of Fertec A......Page 219
11.3 Objectives......Page 220
11.3.1 Comments on objectives......Page 221
11.4.2 Ammonia plant maintenance strategy......Page 223
Life plan for the SGC......Page 224
Ancillary equipment......Page 226
11.5.2 The maintenance resource structure......Page 229
11.5.3 The maintenance administrative structure......Page 232
11.6.1 Short-term work planning, scheduling and control......Page 234
Recommendations......Page 238
Comments and recommendations......Page 240
Comments and recommendations......Page 242
11.8.2 The control of organizational efficiency......Page 243
11.9 Documentation......Page 244
Reference......Page 245
A.1 Weibull analysis of item lifetime......Page 246
A.3 A Weibull analysis of a large and complete sample of times-to-failure......Page 249
F......Page 252
O......Page 253
T......Page 254
Z......Page 255