Anthony Kelly Rimlicey business-centred maintenanceButterworth-Heinemann An imprint of Elsevier Science Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn MA 01801-2041 First published 1997 Reprinted 1998, 1999, 2000 ‘Transferred to digital printing 2002 Copyright © 1997, Elsevier Science Ltd. All rights reserved No part of this publication may be reproduced in any materia! form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England WIT 4LP. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publisher British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 2417 5Contents Preface Acknowledgements ix ‘i ihe nhieGl organization 1 2 Plant acquisition policy and maintenance life-cycle costs 7 Formulating maintenance strategy, a business centred approach 18 4 The structure of plant 31 5 The reliability of plant components 43 6 The reliability of plant systems 66 7 Maintenance objectives 79 8 Principles of preventive maintenance 97 9 Determining the life plan and schedule — the top-down bottom-up approach 141 167 10 — Controlling plant reliabilityvi Contents 11___Case studies in maintenance strategy 176 12 Exercises in maintenance strategy 205 13. Reliability Centred Maintenance 217 14 Total Productive Maintenance — its uses and limitations 231 15. Conclusions 250 Appendix 1 Maintenance terminology 253 Appendix 2 254 In situ repair techniques Index —Csi‘“—sCs‘“‘“‘ W261Preface Devising optimal strategy for maintaining industrial plant can be a difficult task of quite daunting complexity. My aim, therefore, in writing this book, has been to provide the plant engineer with a comprehensive and systematic approach for tackling this problem, i.e. a methodology — or framework of guidelines —for deciding maintenance objectives, formulating equipment life plansand plantmaintenance schedules, designing the maintenance organization and setting up appropriate systems of documentation and control. I have called this approach Business-centred Maintenance (BCM) because it springs from, and is driven by, the identification of business objectives, which are then translated into maintenance objectives and underpin the maintenance strategy formulation. I have developed this approach during more than twenty years’ full-time involvement with maintenance management — teaching it (mostly in-plant), researching its complexities and (more recently) providing industrial consultancy in the subject. Indeed, it is the last of these activities that has had the greatest influence on the content of this book, leading me to modify and expand the approach outlined in my previous books* and enabling me to illustrate it with industrial examples and case studies derived from my own work. Currently, the BCM methodology is being used, by my own partnership** and by other consultancy groups, to audit the maintenance departments of industrial companies with a view to their modification and improvement. It has been adopted as the framework for postgraduate programmes in maintenance management, at the Universities of Manchester (UK) and of Central Queensland (Australia). Parts of it, e.g. the top-down-bottom-up formulation of plant life plan and preventive schedule (see Chapter 9) have been incorporated in maintenance management software (available from MMS, Adelaide and from Mechatricity, Brisbane, Australia). Most publications in this subject area have lacked the analysis of maintenance management principles and structures that is essential for the development of the topic as an academic discipline. I hope that in trying to correct this situation Thave provided a book that will help not only students of industrial management butalso practising maintenance managers. * Management of Industrial Maintenance (with M. J. Harris), Newnes-Butterworths (1978) Maintenance Planning and Control, Butterworths (1984) ‘Maintenance and its Management, Conference Communication (1989) ** International Maintenance Management Specialists (IMMS): A. Kelly, M. J. Harris, H.S. Riddell, A. D. Ball (Associate), P. Bulger (Associate), and T. Lenahan (Associate).viii Preface Chapter 1 takes the systems view of a company and explains that the maintenance sub-system influences — and is influenced by — many other sub-systems. It emphasizes that the capital asset management function has a major effect on the maintenance department via its concern for asset reliability and maintainability and also that, as regards organizational design, the maintenance and production departments are inseparable. Chapter 2 looks at the influence of capital asset acquisition policy on maintenance life-cycle costs. Via an industrial case study, Chapter 3 then develops the overall methodology of BCM. Chapter 4 shows how an industrial plant can be modelled as a hierarchy of inter-related parts and also as a process flow. Chapters 5 and 6 then explain how statistical techniques can be used first to model patterns of component failure and quantify component reliability and secondly to model and assess the reliability of plant systems. As well as showing how business needs determine the development of maintenance objectives Chapter 7 also outlines a hierarchy of such objectives. Chapter 8 then deals with what is probably the key issue in this area, namely preventive maintenance decision-making, discussing the concepts and principles involved and their application to the formulation of a life plan for a unit of plant. Chapter 9 outlines the unique TDBU approach to formulating a preventive maintenance schedule for a plant and Chapter 10 then describes a reliability-based model for controlling the application of maintenance effort. To further illuminate the ideas which have been discussed up to that point, and to reinforce understanding of them, Chapters 11 and 12 present various contrasting industrial case studies and exercises. Finally, Chapters 13, 14 and 15 first review the merits and limitations of the two other basic philosophies of maintenance strategy formulation, namely Reliability centred Maintenance (RCM) and Total Productive Maintenance (TPM) and then compare and contrast them with BCM. This book deals with the general BCM methodology for deciding maintenance strategy, i.e. with the setting of objectives and with the determination of life plans for the various units of an industrial plant and of schedules for the complete plant. A companion book, Maintenance Organization and Systems, deals with the concomitant organizational and control elements of maintenance managementAcknowledgements Iam deeply indebted to my colleague John Harris who most generously contributed Chapters 5, 6 and 13 and also edited the complete text. I would also like to thank Dr Andrew Ball who contributed Table 8.3 and Dr Harry Riddell for the main figures in Chapter 2. The following have also contributed through discussion and correspondence arising out of my own and my IMMS partners’ industrial consulting work: John Abbottand Brian Gover, Comaico, Australia Jim Beckford, Mars Confectionery, UK Alan Bonney, BHP Coal, Australia Colin Bower, ex-QEC, Australia Tony Calloway, Cummins, UK Bill Carr, Alcan, UK Glen Chuter, Alcan, Australia Harry Cockerill, Foster-Wheeler, UK Alan Dundass, Nabalco, Australia David Eiszele, John Collins and Bill Wallace, Western Power, Australia Richard Grey, Courtaulds Chemicals, UK Bent Knauer, Bignumand Stenfor, Denmark Nigel Land, Conoco, UK Peter Mackenzie, MINCOM, Australia Jeff Miller, Peak Gold Mines, Australia David McLatchie, Petroleum Refineries (Australia) Tom Muldoon and Dermot Connellan, ESB, Ireland Jerry Murden, Du Pont Algraphy, UK Peter Mackenzie, MINCOM, Australia Ray Parkin, Capcoal, Australia Norman Peacock, ICL, UK Tan Roberts, ECNZ, New Zealand Liam Tobin, Boyne Smelters, Australia Barry Wilmer, Nissan, UK Mark Zamitt, QAL, Australia I would also like to thank: BillGeraerds, Emeritus Professor of Industrial Engineering, University of Eindhoven, Holland, for help and advice which has greatly influenced my work; Christer Idhammer, Idcon, USA, for his insights into fundamental maintenance concepts;