Maintenance and Reliability Best Practices. Ramesh Gulati

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СКАЧАТЬ APPENDIX B

       SMRP/CMRP Body of Knowledge (BoK) for Maintenance & Reliability Professionals

       APPENDIX C

       Uptime Elements and Asset Life-Cycle Management

       Index

Foreword to the Third Edition

      The Mars rovers Spirit and Opportunity were launched individually in the summer of 2003 and touched down in January of 2004 in different regions of the planet. Each was equipped with a panoramic camera, a macro camera, spectrometers for identifying rocks and minerals, and a little drill for taking samples. The goal was to operate for 90 days, traveling about 40 meters each day and ultimately covering about a kilometer. Both exceeded those goals by incredible amounts. Spirit ended up traveling about 7.7 kilometers and lasting about 7 years.

      Opportunity outshone its twin, going some 45 kilometers over 14 years.

      No maintenance! High reliability.

      The best practice for maintenance is zero. A maintenance-free asset is a dream come true for asset owners. As Ramesh Gulati has taught us for years, the time to influence such an outcome is in early asset life cycles such as specification, design, creation/build and commissioning. The required maintenance is locked in place once the asset begins its operating life. One’s influence on reliability, sustainability, safety, and total cost of ownership are limited after commissioning.

      Yet, most assets are not maintenance-free. You will have to read 10 Rights of Asset Management (ISBN 978-1-941872-83-3) to learn more about the benefits of Reliability-Centered Design (RCD) as we refer to it in Uptime Elements Reliability Framework and Asset Management System or Design for Reliability (DFR) as Ramesh and his colleagues refer to it.

      The issues around determining maintenance requirements for an asset were settled over 40 years ago with Nolan and Heaps seminal work “Reliability–Centered Maintenance” or RCM, commissioned by the Department of Defense in collaboration with United Airlines. The result of a thorough RCM analysis is a “technically valid” and “economically feasible” preventive maintenance strategy that is aimed at safely ensuring that the asset or system will deliver its function at the lowest possible cost.

      Easy to say, much more challenging to do. Reliabilityweb research indicates that over 70% of maintenance improvement initiatives fail to generate sustainable business success, meaning, it never shows up on the financial statement.

      In this book, Ramesh Gulati takes us on a 360-degree journey that includes technical approaches, effective processes, and, most importantly, people in order to reverse the trend of failed improvement efforts with proven strategies and tactics.

      Unlike many authors, Ramesh is both a subject matter expert and an experienced master practitioner with a 40+ year record of highperformance reliability results. He has added so much value in various maintenance and reliability communities by sharing his own knowledge and through encouraging others to share their knowledge. He not only adds insight, but he also changed our perspective by working in “system” thinking, whole life asset management, and ethical humanity.

      Ramesh has always been a “Reliability Sherpa” or guide for the rest of us. He knows it is you who must do the hard work of climbing the maintenance mountain, but he stands with you to let you know about challenges that are just around the corner, and he asks thoughtprovoking questions that allow us to discover for ourselves powerful insights that advance our thinking and our practices.

      This book is also often referenced as one of the best resources for preparing for Professional Certification exams, and I endorse that use highly.

      I suspect that maintainers will use this book 50 years from now to ensure that the infrastructure for our interplanetary settlements and that our speed-of-light flying cars are reliable.

      In the meantime, don’t just use this book as a study guide; use it as your own personal Reliability Sherpa. The lessons it teaches advance as you do, so a one-time read is not enough. This is your go-to reference as you work to achieve reliability and advance asset management.

      Use it well.

      I am grateful for this opportunity.

      Terrence O’Hanlon

      Reliability Leader

      Coauthor, 10 Rights of Asset Management

Preface to First Edition, 2009

      In today’s global economy, we are facing two major challenges:

      • Competitiveness

      • Lack of skilled workforce

      Producing quality products or providing services at competitive prices is essential for surviving in today’s business climate. We are forced to look for better ways of doing things on a continual basis. Satisfying customers’ needs—on their schedule—requires (high) availability and reliability of equipment and systems. We in the maintenance and reliability (M&R) field are constantly challenged to implement the best way to ensure equipment is available when we need it at a reasonable cost. We have come to call these our “best practices.” But it is not as simple as putting something into effect. Truly implementing a best practice requires learning, re-learning, benchmarking, and realizing better ways of ensuring high reliability and availability of equipment and systems.

      This book is designed to support that learning process of implementing best practices in maintenance and reliability.

      Implementing best practices of achieving the optimal reliability and availability of equipment at the optimal cost requires a workforce with a thorough understanding and knowledge of both M&R principles and available technologies. When we say “workforce,” we mean literally everyone. These include designers who design the equipment; operators who operate; maintainers who maintain; warehouse and store personnel who procure and supply materials; engineers who improve the reliability; and human resource professionals who provide and arrange for a work force. Achieving high reliability and availability requires teamwork.

      Although there are many books available in this field, most of them are focused on a specific practice, e.g., Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM), Benchmarking, Lean Maintenance, and Performance Measurements. This book takes a more basic approach. It provides an overview of key best practices, how to implement them and measure their effectiveness, and offers the best M&R practices to increase understanding of M&R to everyone currently or looking to be in the workforce of an organization.

      August 2020

      I would like to give special thanks to my colleagues Lynn Moran, Sherry Stovall, Tommy Northcott, Steve Bollman, Marie Getsug, Nick Jize, and Christopher Mears for reviewing third edition manuscripts and providing very valuable feedback.

Acknowledgments

      First, I want to thank you, my readers, who have read previous editions of this book or are going to read this new edition. Over the years, since the first edition was published in 2009, I have received great feedback via many emails, reviews on Amazon, messages to Industrial Press, social СКАЧАТЬ