Managing Maintenance Resources (eBook)

Anthony Kelly (Autor)

eBook Download: PDF

2006 | 1. Auflage
312 Seiten
Elsevier Science (Verlag)
978-0-08-046261-5 (ISBN)

Infos

Managing Maintenance Resources shows how to reduce the complexity involved in engineering, or re-engineering, a maintenance organization. It recognises that this is a complex problem involving many inter-related decisions - such as whether or not resources should be centralized, contractor alliances be entered into or flexible working be adopted. This book provides a unique approach to modeling maintenance-production organizations. It enables the identification of problems and delivers guidelines to develop effective solutions.

This is one of three stand-alone volumes designed to provide maintenance professionals in any sector with a better understanding of maintenance management, enabling the identification of problems and the delivery of effective solutions.

* The second of three stand-alone companion books, focusing on reducing the complexity of organizational design
* Covers the maintenance of plant, production and operations assets in industry and service sectors, including manufacturing, food and process engineering, minerals and mining, transport, power and IT
* Includes review questions, exercises and case studies
* Clearly specified objectives and learning outcomes are given for each chapter, including a route map to link each chapter to the rest of the topics covered

Inhalt

Cover 1
Contents 6
Preface 12
Acknowledgments 14
Author's biography 16
Part 1 Introductory chapters 18
1 A business-centered approach to maintenance organization 20
1.1 Introduction 21
1.2 Business-centered maintenance 21
1.3 An example of the application of BCM: background 22
1.4 Part A: Audit of the FPP maintenance department 24
1.4.1 Maintenance objectives 24
1.4.2 Life plans and preventive schedule 25
1.4.3 Workload 28
1.4.4 Maintenance organization 30
Resource structure 30
Administrative structure 32
1.4.5 Maintenance work planning 33
1.4.6 Maintenance control system 35
1.4.7 Maintenance documentation 36
1.4.8 Audit summary 38
1.5 Part B: An alternative maintenance strategy for continuous operation 39
1.6 Part C: A longer-term view of organizational change 40
1.7 The strategic thought process 40
References 41
2 Maintenance organization in outline 46
2.1 Introduction 47
2.2 Modeling the organization 48
2.3 Factors influencing the design of the maintenance organization 50
3 The maintenance workload 56
3.1 Introduction 57
3.2 Categorization of the maintenance workload 57
3.3 Mapping the workload 60
3.3.1 First-line workload 60
3.3.2 Second-line workload 62
3.3.3 Third-line workload 63
3.4 Forecasting the maintenance workload 63
3.4.1 First-line workload 64
3.4.2 Second-line workload 64
3.4.3 Third-line workload 65
3.5 Case studies in categorizing and mapping the maintenance workload 66
3.5.1 Ammonia plant 66
3.5.2 Chemical plant 66
3.5.3 Agricultural chemicals 67
3.5.4 Alumina refining 68
Part 2 Maintenance organizational concepts, trends and mapping 72
4 Maintenance resource structure 74
4.1 Introduction 75
4.2 Mapping the resource structure 75
4.3 Resource characteristics 79
4.3.1 Manpower 80
4.3.2 Spare parts 80
4.3.3 Tools 81
4.3.4 Information 81
4.4 A decision model for the design or modification of a resource structure 84
4.5 The key decision-making areas of resource structuring 85
4.5.1 Contract labor 85
4.5.2 Trade-force composition 88
4.5.3 Plant specialization 91
4.5.4 Trade-force location 91
4.5.5 Non-daywork maintenance cover 92
4.5.6 Sizing the trade-force 94
4.5.7 Locations of spares, tools and information 95
4.5.8 Logistics 96
4.6 A systematic procedure for determining a resource structure 96
4.6.1 For a new plant 96
4.6.2 For an existing resource structure 98
4.7 Summary 101
5 Maintenance administrative structure 106
5.1 Introduction 107
5.2 Modeling administrative structures 107
5.3 Traditional views on administrative management and some guidelines 108
5.4 Characteristics of maintenance administrative structures 114
5.4.1 The maintenance–engineering interface 114
5.4.2 The maintenance–production interface 116
5.4.3 Responsibility for spare parts management 120
5.4.4 Vertical polarization 120
5.4.5 The relationship between the professional engineer and the maintenance supervisor 121
5.4.6 Major overhaul administration 121
5.4.7 Summary 123
5.5 The design or modification of the administrative structure 124
References 126
6 Human factors in maintenance management 128
6.1 Introduction 129
6.1.1 What are 'human factors' in organizations? 129
6.2 The human relations approach to management: a brief review 130
6.3 Maintenance management behavioral characteristics 131
6.3.1 Individual behavioral characteristics 132
Equipment ownership 132
Goodwill 133
Motivation 134
Morale 134
Resentment 135
Protectionism 135
Parochialism 136
Other human factors 136
6.3.2 Group behavioral characteristics 137
Culture 137
Esprit de corps 137
Horizontal polarization 137
Vertical polarization 139
6.4 The effect of outsourcing alliances 140
6.5 Auditing maintenance management human factors 141
References 142
7 Trends in maintenance organization 144
7.1 Introduction 145
7.2 Traditional maintenance organizations 145
7.3 Centralized resource structures 146
7.4 Introduction of flexible working practices 150
7.5 Plant manufacturing units 153
7.6 Slimming the structure ('downsizing') 156
7.7 The movement toward self-empowered plant-oriented teams 159
7.8 Contracting, outsourcing and alliances 162
7.9 Summary 164
References 166
Part 3 Maintenance organization case studies 168
8 Case study 1: Moving with the times 170
8.1 Introduction 171
8.2 Background 171
8.3 Audit of the CMG 173
8.4 Setting up the alliance 179
8.5 Observations 181
References 184
9 Case studies 2 and 3: Cautionary tales of organizational change 186
9.1 Introduction 187
9.2 Case study 2: A bottling plant 187
9.2.1 Background 187
9.2.2 The plant maintenance strategy and organization 188
9.2.3 Organizational change: the way forward 190
9.2.4 Short-term actions 191
9.3 Case study 3: An aluminum rolling mill 192
9.3.1 Background 192
9.3.2 Plant-operating characteristics and objectives 194
9.3.3 Life plans and preventive schedules 194
9.3.4 An overview of the organization 195
9.3.5 Maintenance systems 198
9.3.6 Observations and recommendations 199
10 Case study 4: Reorganization of a colliery 202
10.1 Introduction 203
10.2 Maintenance consultancy at COALCOM – 1994 203
10.2.1 Background to COALCOM 203
10.2.2 Equipment and operating characteristics 204
10.2.3 Production and maintenance objectives 206
10.2.4 Life plans and preventive schedule 206
10.2.5 Maintenance organization 208
Resource structure 208
Administrative structure 210
10.2.6 Maintenance systems 213
10.2.7 Recommendations 213
10.3 Progress visit and consultancy – 1997 218
10.3.1 Introduction 218
10.3.2 Organization 218
10.3.3 Life plans and preventive schedule 221
10.3.4 Recommendations – 1997 221
11 Case study 5: The do's and don'ts of maintenance teams 226
11.1 Introduction 227
11.2 Characteristics of teams at Fertec B 227
11.3 Characteristics of teams at Cario 230
11.4 Improving team operation at Fertec B 231
11.5 General comments on maintenance teams 232
Reference 233
12 Case study 6: Maintenance audit of an agricultural chemical plant 236
12.1 Introduction 237
12.2 An overview of Fertec A 237
12.3 Objectives 239
12.3.1 Comments on objectives 239
12.4 Maintenance strategy 241
12.4.1 Plant-operating characteristics 241
12.4.2 Ammonia plant maintenance strategy 241
Life plan for the SGC 243
Life plan for pressure vessels 244
Ancillary equipment 244
Electrical/instrumentation equipment 247
12.5 Maintenance organization 249
12.5.1 Introduction 249
12.5.2 The maintenance resource structure 249
Recommendations 253
Proposal A 253
Proposal B 253
12.5.3 The maintenance administrative structure 253
Recommendations 256
Proposal A 260
Proposal B 260
Part 4 Total productive maintenance 262
13 Total productive maintenance: its uses and limitations 264
13.1 Introduction 265
13.2 What is TPM? 265
13.3 An early case study 266
13.4 Fundamentals of TPM 270
13.5 European applications by non-Japanese companies 273
13.6 Summary 278
References 281
Part 5 Exercises 284
14 Course exercises 286
14.1 Exercise E14.1: The changing role of the maintenance supervisor 286
14.1.1 Background 286
14.1.2 Part A: The supervisor's role in a traditional organization 287
14.1.3 Part B: The role of the supervisor after a 'downsizing' exercise 287
14.1.4 Part C: Introduction of self-empowered work teams 289
14.2 Exercise E14.2: Maintenance reorganization in a food processing plant 291
14.2.1 Background 291
14.2.2 Company organization and maintenance strategy 293
14.2.3 The problem 297
Index 306
A 306
B 306
C 306
D 307
E 307
F 307
G 307
H 307
I 307
J 307
K 307
L 307
M 307
N 308
O 308
P 308
Q 309
R 309
S 309
T 309
U 309
V 309
W 309

Produkt-Details

• Erscheint lt. Verlag: 22.6.2006
• Sprache: englisch
• Themenwelt: Technik ► Elektrotechnik / Energietechnik
• Themenwelt: Wirtschaft ► Betriebswirtschaft / Management ► Logistik / Produktion
• Themenwelt: Wirtschaft ► Betriebswirtschaft / Management ► Unternehmensführung / Management
• ISBN-10: 0-08-046261-8 / 0080462618
• ISBN-13: 978-0-08-046261-5 / 9780080462615