World Class Maintenance Management

Title
Contents
1. World Class Manufacturing Company
	1. Are you a World Class Manufacturing Company?
		1.1 Product Quality
			1.2 Know the Requirements of Key Customers
				1.3 Perfect Delivery
				1.4 Eliminate Inventory at all Levels
				1.5 Empowered Staff
				1.6 Minimize Distance between Sequential Operations and Increase Product Flow
				1.7 Set-up Time Reduction (SMED)
				1.8 Training and Education
				1.9 Initiative
			1.10 Reduction of Non-Value-Adding Activities
			1.11 Rationalization of Suppliers
			1.12 Total Quality Culture
			1.13 Audit
			1.14 Mistake-proofi ng
			1.15 Authority to Stop
			1.16 Users are Equipment “Owners”
			1.17 Good Housekeeping
			1.18 Product Design to Involve all Departments
			1.19 Continuous Improvement
			1.20 Feedback from Customers and Employees
			1.21 So Simply what is “World Class Manufacturing”?
			1.22 What is Value Added Activity?
			1.23 Just-in-Time Delivery
			1.24 Total Flexibility
			1.25 Shortest Cycle Time
			1.26 Speed to Market
			1.27 Learning Organization
			1.28 Best Customer Relations
			1.29 What are the Pressures on Manufacturing Function?
2. Elements of Manufacturing Cost
	2.1 Cost of Raw Materials and Packaging Materials
		2.2 Direct Labor
			2.3 Overheads
			2.4 Contribution of “World Class Maintenance” to the Business
			2.5 Where Savings Come From?
			2.6 What are Key Elements of Maintenance Cost?
3. Role of Maintenance Department
	3.1 Support to Jishu Hozen or Autonomous Maintenance
		3.2 Coaching and Guidance to Production Operators
			3.3 Leading Role in 5S Activity
			3.4 Attending Breakdowns
			3.5 Analyzing Major Breakdowns
			3.6 Implementing Preventive Maintenance
			3.7 Implementing Condition Based Maintenance (CBM)
			3.8 Spare Parts Stores Management
			3.9 Enhancing MTBF (Mean-Time-Between-Failures) and Reducing MTTR (Mean Time to Repair)
		3.10 Leading Role in Kaizen
		3.11 Identify Measures of Performance and Track them
4. Objectives of World Class Maintenance Management
	4.1 Improving Availability
		4.2 Improving Reliability
			4.3 Concept of Bath Tub Curve
			4.4 Front End Engineering
			4.5 Life Cycle Costing
			4.6 Customer Feedback
			4.7 Design Inputs from the user or MP Data
			4.8 Inspection of the Equipment Fabrication or Manufacturing Activity
			4.9 Installation and Commissioning
		4.10 The Second Stage or Youth Stage
		4.11 Elimination of Natural Deterioration
		4.12 The Third Stage or Old-Age Stage
5. Six Steps of Progressive Maintenance
	5.1 How Do We Start (Six Steps of PM)
		5.2 Step-by-Step Development Process of Progressive Maintenance Activity
			5.3 Step 2. Reverse Deterioration and Correct Weaknesses
			5.4 Step 3. Build an Information Management System
			5.5 Step 4: Build a Periodic Maintenance System
			5.6 Step 5: Build a Predictive Maintenance System
			5.7 Step 6: Evaluate the Progressive Maintenance System
6. Basic Concept of Progressive Maintenance Activities
	6.1 Basic Concept of Progressive Maintenance Activities
		6.2 Structures and Work Processes
			6.3 Planning and Scheduling
			6.4 Information System
			6.5 Lubrication Management
			6.6 Maintenance Costs
			6.7 Tools and Skills
			6.8 Equipment/Spares/Rebuilds
			6.9 Guidance and Support Activities for Autonomous Maintenance (Jishu Hozen)
		6.10 Countermeasures to Breakdowns
		6.11 Maintenance Improvement Activities
		6.12 Maintenance Prevention Activities
		6.13 Implementation of Predictive Maintenance
7. Theory of Breakdowns
	7.1 Physical Analysis of Breakdowns
		7.2 Forced Deterioration
			7.3 Natural Deterioration
			7.4 Uncontrolled Stress
			7.5 Insuffi cient Design Strength
			7.6 Factor Analysis to Achieve Zero Breakdowns
			7.7 Inadequate or No Compliance with Basic Requirements
			7.8 Neglected Deterioration
			7.9 Non-compliance with Usage Requirements
		7.10 Lack of Skill
		7.11 Inherent Design Weakness
8. Nine Pillars of Maintenance Management
	8.1 Breakdown Maintenance
		8.2 Preventive Maintenance
			8.3 Corrective Maintenance
			8.4 Autonomous Maintenance (Jishu Hozen)
			8.5 Opportunistic Maintenance or “If Down Do”
			8.6 Predictive Maintenance (Condition Based Maintenance)
			8.7 Reliability Centered Maintenance (RCM)
			8.8 Lubrication Management
			8.9 Engineering Stores
9. How to Organize for Establishing Good Maintenance Practices?
	9.1 Assess Where You are Today
		9.2 World Class Maintenance Management Audit Sheet
10. Maintenance Prevention
	10.1 What is MP Design?
11. How to Make Maintenance More Effi cient Using 5S Principles
	11.1 What is 5S
		11.2 How to Implement 5S
			11.3 How to Implement 5S in Maintenance Department
12. Role of Leadership in Maintenance Function
	12.1 Importance of Strong Leadership
		12.2 Walk the Talk
			12.3 Learn by Doing and Lead by Coaching
			12.4 3Es of Leadership Behaviors
			12.5 Leadership Traits for Implementing World Class Maintenance
13. How to Develop Ownership in Maintenance Technicians?
	13.1 Learning New Techniques
		13.2 Implementing What They Learned
			13.3 Have Clear Accountability of What They Do
			13.4 Take Leadership and Show it to Others
			13.5 Make it a Demonstration Piece
			13.6 Excel in What You Do
			13.7 Institute Reward System
14. Role of Kaizen in Maintenance Function
	14.1 How to Start Kaizen Activities
		14.2 Structured Approach
			14.3 Training
			14.4 Technical Help
			14.5 Implement the Kaizen
			14.6 Kaizen Presentation
			14.7 Unstructured Approach
			14.8 Methodology of Unstructured Approach
			14.9 How do we Start Kaizen in Maintenance Function?
		14.10 Kaizen Documentation
15. How Does Value Engineering Help in Maintenance?
16. Role of Visual Control in Maintenance
	16.1 Identifi cation Marks
		16.2 Identifi cation of the Contents
			16.3 Identifi cation of Normal Vs. Abnormal
			16.4 Indication of Flow
			16.5 Indication of Caution
			16.6 How are These Visual Controls used for the Maintenance Function?
17. Journey to Achieve Zero Breakdowns
	17.1 Phase 1: Reduce Variation of Component Life Span
		17.2 Phase 2: Prolong Life Span of Specifi c Parts
			17.3 Phase 3
			17.4 Establish Replacement Period (RP 3)
			17.5 Improve Maintainability
			17.6 Detect Abnormalities by Six Senses of the Operator
			17.7 Classify Trend or No Trend
			17.8 Phase 4
18. Progressive Maintenance Total System
	18.1 Purchase Function
		18.2 Engineering (Manufacturing Services)
			18.3 Standardization Requirements
			18.4 Operability Requirements
			18.5 Maintainability Requirements
			18.6 MP Design Requirements
			18.7 Reliability Requirements
			18.8 Spare Parts Store Room
			18.9 Restoration
		18.10 Identify Developing Failures Early
		18.11 Managing Planned and Unplanned Maintenance
		18.12 Maintenance Records
		18.13 Effectiveness Measurement
		18.14 Journey to Achieve Zero Breakdowns
		18.15 Technical Data Base
19. Performance Measures for the Maintenance Function
	19.1 Identify Your “Performance Measures”
		19.2 Preventive Maintenance Time Ratio: (TBM + CBM)/(TBM + CBM + BM)
			19.3 Cost of Maintenance
			19.4 Mean Time to Repair (MTTR)
			19.5 Number of Kaizens Implemented in Maintenance
20. Industrial Safety Maintenance
	20.1 Unsafe Work Methods and Practices
		20.2 Lack of Maintenance and Certifi cation of Lifting Tackles
			20.3 Bad Flooring
			20.4 Bad Layout and Installation
			20.5 Lack of Comprehensive Firefi ghting System
			20.6 Lack of Awareness
			20.7 Building Safety
			20.8 Overloading and Uneven Usage of the Building Spaces
			20.9 Natural Calamities
			20.10 Fatigue
			20.11 Lack of Controls and Work Permits
			20.12 Transportation
			20.13 Boilers and Pressure Vessels
			20.14 Safety of Robotic Equipment
			20.15 Health Hazards
			20.16 Maintenance is a High-risk Activity
			20.17 Regular Maintenance
			20.18 Industrial Safety
21. Maintenance Forecasting, Planning and Scheduling
	21.1 Maintenance
	21.2 Maintenance Strategy
	21.3 Maintenance Forecasting and Planning
	21.4 Forecasting Defi ned
	21.5 Why Forecast?
	21.6 Forecast Principles
	21.7 Qualitative Techniques
	21.8 Types of Maintenance Programs
	21.9 Maintenance Planning and Scheduling
	21.10 Why is Maintenance Diffi cult to Control?
	21.11 Planning & Scheduling of Maintenance Work
22. Managing Turnaround Maintenance
	22.1 What is a Plant Maintenance Turnaround?
	22.2 Plant Turnaround Philosophy
	22.3 Turnaround Management Process
	22.4 Turnaround Management Organization
	22.5 Turnaround Team
	22.6 Contractor Management
	22.7 Scope Management
	22.8 Planning Management
	22.9 Scheduling
	22.10 Communication
	22.11 Approvals
	22.12 Execution Management
	22.13 Tracking of Costs
	22.14 Invoice Verifi cation
	22.15 Logistics
	22.16 Work History Retention
	22.17 Turnaround Closeout
23. Computerized Maintenance Management System (CMMS)
	23.1 Description
	23.2 Applications
		23.3 Lessons Learned
		23.4 Emerging Issues
24. Warranty and Maintenance
	24.1 Additional Defi nitions
	24.2 Implied and Express Warranties
	24.3 Elements of a Warranty
	24.4 Full and Limited Warranties
	24.5 Service Contract
	24.6 Preventing Problems
	24.7 Warranty Maintenance
	24.8 Fundamentals of 8-D Methodology to Address Customer Complaints and Warranty Claims and Resolve Them
	24.9 Warranty Repair or Replacement
	24.10 Product Recall
	24.11 Insurance Claims
	24.12 After-sales Service
	24.13 Warranty Maintenance
Index