Implementing Preventive Maintenance for Industries the Right Way: 5th Discipline on World Class Maintenance Management - Softcover

Angeles, Rolly

Softcover

ISBN 13: 9798885260053

Publisher: Rolando Santiago Angeles, 2022

Synopsis

This book refers to Discipline Number 5 based on the original book I wrote in 2009 on World Class Maintenance - The 12 Disciplines. Almost all industries have their Preventive Maintenance, but still, many problems emerged and the question is can we do something about it?  Many maintenance people from industries are not satisfied with their current Preventive Maintenance even if they are complying with every single maintenance task listed. 
 
My intention in writing this book is to provide a guide and direction to help maintenance in industries get the results in doing the correct Preventive Maintenance on their equipment and assets.  In today's digitalization era, and with all these advanced CMMS and EAM software, apps, technology, cloud, smart sensors, the Industrial Internet of Things, and automation, the majority of industries are jumping on the bandwagon thinking that these technologies will optimize their asset.  I have nothing against technology, but what I am stating is that everything will boil down to one thing and that is addressing the basics first.  The goal and objective of having Preventive Maintenance is to prevent or anticipate a failure or breakdown from happening first.  The keyword in this case is being first.  This means that we need to perform an activity or task before failure happens.  But the thing is we need to be precise in what failures can be addressed by PM since not all failures can be prevented in the first place.  Here are some of the highlights of this book.
 
* The Traditional Belief in Preventive Maintenance
* Mistaken Belief about Preventive Maintenance
* The 3 Phases of Preventive Maintenance
* Why Most Planners Cannot Plan Future PM Work
* Integrating Precision Maintenance on PM
* PM Interval, Are We Doing PM Too Late or Too Soon?
* Determining the Correct Interval for PM Overhauls and Replacement
* Determining the Correct Interval for PM Human Inspection
* Selecting the Maintenance Interval for Greasing Bearings
* Selecting the Maintenance Interval for Changing Oil
* Selecting the Maintenance Interval for Failure Finding Tasks
* Selecting the Maintenance Interval for Redundant Components
* Refining the PM Interval
* Factors to Consider in Stocking Parts or Not In the Storeroom
* MRO Decision Diagram on Whether to Stock or Not to Stock
* Case Samples on How to Use the MRO Algorithm and Form
* Why Operators Should be Involved in Maintenance
* Tips on How to Involve your Operators in Maintenance
* The Role of Predictive Maintenance on PM
* The Reason RCM Was Developed by the Airline Industry
* What the PM Task Should Include
* Measuring PM Effectiveness and Performance
* Maximizing the Use of CMMS
* What CMMS Should Provide for PM
* 21 FAQs on Preventive Maintenance
* 17 Tips on Preventive Maintenance
* Improving Routine Preventive Maintenance Inspection
* Improving Major Preventive Maintenance Shutdown
* Improving Scheduled Greasing Practices
* Treat Maintenance Not as a Profit Center but as a Business

About this title

About the Author

• Rolly Angeles is a seasoned technical and international reliability and maintenance trainer and consultant. His portfolio of reliability and maintenance training includes maintenance management and reliability courses on Total Productive Maintenance (TPM), Planned Maintenance, Autonomous Maintenance, Lubrication Strategy, Tribology, Oil Contamination Control, Condition-Based, Predictive Maintenance, Reliability-Centered Maintenance (RCM), Root Cause Failure Analysis (RCFA), Planned Maintenance, World Class Maintenance Management (WCM), Proactive Maintenance, Maintenance Indices, KPI and more.
• Rolly is a graduate of Mechanical Engineer from Mapua Institute of Technology in the Philippines, batch 1985, and passed the Licensure Board Examination the following year in 1986. With 30 years of solid experience, he had worked in various industries from shipping, woodworking, foundry, cast-iron machining, assembly lines, semiconductor manufacturing, and the mining industry. From 1994 to 2002, Rolly worked as a TPM senior engineer at Amkor Technology Philippines, a Multi-National company engaged in the manufacture of integrated circuit products, and spearheaded Amkor's Planned Maintenance Organization, composed of maintenance managers and engineers. He was responsible for the dramatic reduction of their machine's unplanned breakdowns in their TPM journey as well as RCM implementation on their facilities and utilities Air Handling Units (AHU) and their sub-station equipment. Here is where he had gained hands-on experience and understanding of both TPM and RCM, respectively. His last corporate employment was in 2002, where he worked as a technical training specialist at Lepanto Consolidated Mining Industry.
• In 2005, Rolly retired early from the industry and decided to establish his own consulting business, RSA Reliability and Maintenance Consultancy Firm, where he dedicates his time and passion to work as an independent reliability and maintenance consultant and provi

From the Back Cover

RSA Reliability and Maintenance Book Series

• World Class Maintenance Management-The 12 Disciplines: Many industries are looking for ways to achieve a World Class Maintenance Management Level. The book is easy to absorb as it is structured into three parts: the Basics, the Strategies, and the Advance Disciplines. This book aims to address the very basics first before doing the strategies and the more advanced disciplines. This is the first of a series of books I wrote and still writing about the 12 disciplines of maintenance.

• Maintenance-Roadmap to Reliability: This is a sequel to my first book on World Class Maintenance Management the 12 Disciplines. This book provides a detailed systematic roadmap on how to achieve a high level of reliability for industries' equipment and assets. There is no better way to start the journey to reliability other than to go back to the basics and address the very small problems we have in our plant.

• Reliability-A Shared Responsibility for Operators and Maintenance: This book is a sequel to my first and second book and speaks about the importance of having an operator and maintenance partnership for industries. The message of this book is simple and straightforward industries cannot escape the vicious cycle of being reactive unless they realize the importance of operators in the reliability strategy. It is time for the separation between operators and maintenance to end and finally a partnership to begin.

• Cutting-Edge Maintenance Management Strategies: This book also a sequel deals with the different cutting-edge maintenance strategies that must be adopted by industries for them to survive their competition. In industries today, the law of the jungle applies, survive or be left behind. Learn how these strategies can link together in building a solid maintenance structure in the plant. Finally understand Learn these cutting-edge maintenance strategies in helping build a reliability culture for industries.

• Problems and Solutions on MRO Spare Parts and Storeroom: This book is also a sequel to World Class Maintenance Management book that deals with the common problems on MRO Spare Parts and provides detailed recommendations on how to deal with the day-to-day problems of the storeroom and MRO Spare Parts. An algorithm or MRO Decision Diagram is provided in this book to determine what parts need to be stocked or not in the storeroom.

• Lubrication Tactics for Industries Made Simple: An easy-to-read book that provides the different strategies that can be applied to lubricating grease and oil for equipment and assets to lessen the cost not only of their lubricants but also of failures attributed to lubrication failures. These proven strategies for greasing, lubrication, and contamination control will save your industry not only on lubrication costs but on reducing failures attributed to lubrication failures.

• Decoding Reliability-Centered Maintenance for Manufacturing Industries: This is a detailed and easy-to-read book designed for manufacturing industries on how to implement RCM to their equipment and assets successfully as these industries not only suffer from failures and breakdowns but other losses as well.

• RSA Reliability and Maintenance Newsletter Vault Collection: This is a complete collection of reliability and maintenance newsletter archives which I started writing in May 2007. These maintenance newsletters cover a wide range of topics and important information on the different disciplines of maintenance.

• Investigating Equipment Failures Through Root Cause Failure Analysis: When an equipment failure happens, we need to accept it, learn from it, challenge it and finally overcome the failure. This means that when an incident happens, we have two options, either we learn from them or just ignore them. The message of Root Cause Failure Analysis is simply to take the first option and learn from the failure.

• Maintenance Indicators - Meaningful Measures of Equipment Performance: This book covers the different maintenance indicators and KPIs that can be used for different industries to determine if they are in the right direction on maintenance. What is important is for maintenance to understand what to include and not in these indices and KPIs.

• Implementing Preventive Maintenance for Industries the Right Way: This book is written for industries who want to improve and benefit from their Current Preventive Maintenance activities done on their equipment and assets. Learn and understand what Preventive Maintenance can and cannot do.

From the Inside Flap

• To answer the question, why doesn't Preventive Maintenance reduce the amount of reactive maintenance being performed in the plant? Preventive Maintenance is a good strategy, but most industries simply abuse, misuse, or overuse its concept making PM more reactive. My experience tells me that activities included in the PM checklists continue to grow daily due to deviations from audits, customer issues, quality and safety issues, day-to-day breakdowns, and so on. We must understand that the lesser the amount of PM performed on the equipment, especially those that involved coming in contact, the better the equipment will run smoothly. Intrusive or forced maintenance will only create more problems in operations.
• Our people must understand and realize the lessons from Nowlan, Heap, Mentzer, and Matteson that there are not one, not two, but six types of failure patterns in the real world of doing maintenance. This means that every single part or spare we have in our equipment may actually fail according to any of these six failure patterns. Not all parts of our equipment will wear out just like people. The majority of failures we experienced in the past in the equipment are random failures and premature wear. If industries are experiencing many random failures, Preventive Maintenance is not the solution. Remember that Preventive Maintenance was designed around the theory that equipment failures are directly related to the equipment's age. In reality, only around 20 to 30% of equipment failures will fit this pattern, which means that 70 to 80% of equipment failures will not be managed effectively by doing time-based or scheduled Preventive Maintenance activities.

Edition details

• Publisher: Rolando Santiago Angeles
• Publication date: 2022
• Language: English
• ISBN 13: 9798885260053
• Binding: Paperback
• Edition number: 5
• Number of pages: 344