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أخواني في الله أحضرت لكم كتاب Rules of Thumb for Maintenance and Reliability Engineers Ricky Smith and R. Keith Mobley
![كتاب Rules of Thumb for Maintenance and Reliability Engineers R_o_t_11](https://i.servimg.com/u/f61/15/36/74/14/r_o_t_11.jpg) 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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