Maintenance and Operational Reliability

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The quest for reliability is long overdue! In the case of many operations, realization of sustained reliability is still a work in progress. Very few organizations have completed the journey to world-class reliability. The vast majority still operate within a reactive culture, allowing response to repetitive failures to consume an excessive proportion of already limited maintenance resources, and leaving too few for performance of any proactive activities.

In today’s competitive international environment, enterprise survival is a battle of the fittest. To survive, organizations must achieve “world-class” stature, characterized by wellness, readiness, and application required for a company to successfully compete globally. That’s why Maintenance and Operational Reliability is so important.

This work is organized by the foundation and 5 Pillars of Maintenance/Reliability Excellence, plus 24 Building Blocks, as depicted throughout the book. This pillar graphic shows the functions, management techniques, systems, information sources and performance management vital to the maintenance and reliability process, and also serves as an important visual aid for the education of the entire organization.

So, how is the ultimate, but challenging reliability goal to be achieved? Are you prepared to manage, support, process, and interpret the magnitude of information in real time, critical to making the right business decisions to achieve a competitive advantage? The authors, two veteran maintenance and reliability experts, have collected all the essentials leading to reliability here, in one practical resource, connecting and sequencing the integral pieces for world-class reliability.

Features

• Guides readers through the journey from classic reactive repair upon failure to reliable, proactive maintenance, engineered to preclude failure and, ultimately, to sustain reliability.
• Clarifies roles and responsibilities of involved functions while explaining control tools to be deployed by each position.
• Provides the overriding business justification required to gain senior management commitment.

Donald Nyman has been an industrial engineer, corporate executive, and management consultant for more than 60 years, guiding and supporting facility, maintenance, and reliability endeavors at local, division, and corporate levels.

Bill Mountjoy has spent over 25 years implementing best practice methodologies in maintenance and reliability excellence for several Fortune 100 manufacturing companies, supporting over 150 operations around the globe. He has conducted a multitude of training sessions and assessments of plant teams on maintenance reliability effectiveness.

Contents

A: PROCESS FOUNDATION:
1. Governing Principles, Strategies, & Policies

B: PERFORMANCE MANAGEMENT
2. Status Assessment
3. Master Plan
4. Objectives, Goals, & Targets
5. Budgetary Control
6. Management Reporting & Control

C: ORGANIZATIONAL DEVELOPMENT
7. Organization Size & Structure
8. Supervisory Practices
9. Education & Training

D: INFORMATION SOURCES
10. Sources of Management / Operational Information;

E: OPERATIONAL CONTROL
11. Macroplanning
12. Microplanning of Individual Jobs
13. Materials Support & Control
14. Work Measurement
15. Inter-Functional Coordination
16. Job Scheduling

F: ASSET RELIABILITY:
17. Reliability Engineering & PM/PdM
18. Technology-Enhanced Asset Reliability

App. A. Sample Maintenance Assessment

App. B. Sample Maintenance / Reliability Excellence Master Plan.