CM 3355 Module 6

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Maintenance Schedule

- a list of planned maintenance tasks to be performed during a given time period, together with the expected start times and durations of each of these tasks. Schedules can apply to different time periods (e.g. Daily Schedule, Weekly Schedule etc.)

Unscheduled Maintenance

- any maintenance work that has not been included on an approved Maintenance Schedule prior to its commencement

Reliability

- the capability of an asset to continue to perform its intended functions. Normally measured by Mean Time Between Failures

Emergency Work

- unscheduled work that requires immediate attention

KPI = Key Performance Indicators

A select number of key measures that enable performance against targets to be monitored

RCM = Reliability Centered Maintenance

A structured process, originally developed in the airline industry, but now commonly used in all industries to determine the equipment maintenance strategies required for any physical asset to ensure that it continues to fulfil its intended functions in its present operating context. A number of books have been written on the subject, but none better than Moubray's book, RCM II

Non-routine Maintenance

Any maintenance task which is not performed at a regular, predetermined frequency

Inspection

Any task undertaken to determine the condition of equipment, and/or to determine the tools, labor, materials, and equipment required to repair the item

Proactive Maintenance

Any tasks used to predict or prevent equipment failures

This maintenance craft job description includes - Constructing, erecting, installing, fabricating, dismantling and repairing structures, formwork and fixtures of wood, metal forms, and associated accessories:

Carpenter

Benefits of a preventive maintenance program include:

Decreased equipment downtime and major repairs. Increased equipment life expectancy, eliminating premature equipment replacement. Reduced overtime costs due to employees working on a schedule as opposed to an emergency basis to attend to repairs and breakdowns. Reduction in large-scale repairs. Improved safety and conditions for employees.

The main objectives of preventive maintenance are as follows:

Enhance asset/equipment productive life. Reduce critical equipment breakdowns. Minimize production loss due to equipment failures

This maintenance craft job description includes - Raising, placing and uniting girders, columns and other structural-steel members to form completed structure frameworks:

Ironworker

Any activity carried out on an asset to ensure that the asset continues to perform its intended functions or to repair the equipment:

Maintenance

Shutdown Maintenance

Maintenance that can only be performed while equipment is shutdown

Designed to help determine the condition of in-service equipment to indicate in advance when maintenance should be performed:

Predictive Maintenance

The care and servicing by personnel to maintain equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of failures either before they occur or before they develop into significant defects:

Preventive Maintenance

The capability of an asset to continue to perform its intended functions. Normally measured by mean time between failures.

Reliability

Generally used to achieve improvements in fields such as the establishment of safe minimum levels of maintenance, changes to operating procedures and strategies, and the establishment of capital maintenance regimes and plans:

Reliability Centered Maintenance

The 3 Elements of Preventative Maintenance

Systematic Performed routinely Aimed at reducing or minimizing failures

Purchase Order

The prime document raised by an organization, and issued to an external supplier, ordering specific materials, parts, supplies, equipment or services

Purchase Requisition

The prime document raised by user departments authorizing the purchase of specific materials, parts, supplies, equipment or services from external suppliers

Work Order

The prime document used by the maintenance function to manage maintenance tasks. It may include such information as a description of the work required, the task priority, the job procedure to be followed, the parts, materials, tools and equipment required to complete the job, the labor hours, costs and materials consumed in completing the task, as well as key information on failure causes, what work was performed etc

Backlog

Work which has not been completed by the nominated 'required by date'. The period for which each Work Order is overdue is defined as the difference between the current date and the 'required by date'. All work for which no 'required by' date has been specified is generally included on the backlog. Backlog is generally measured in "crew-weeks", that is, the total number of labor hours represented by the work on the backlog, divided by the number of labor hours available to be worked in an average week by the work crew responsible for completing this work. As such, it is one of the common Key Performance Indicators used in maintenance.

Scheduled Work Order

a Work Order that has been planned and included on an approved Maintenance Schedule

TPM = Total Productive Maintenance

a company-wide equipment management program, with its origins in Japan, emphasizing production operator involvement in equipment maintenance, and continuous improvement approaches

CMMS = Computerized Maintenance Management System

a computerized system to assist with the effective and efficient management of maintenance activities through the application of computer technology. It generally includes elements such as a computerized Work Order system, as well as facilities for scheduling Routine Maintenance Tasks, and recording and storing Standard Jobs, Bills of Materials and Applications Parts Lists, as well as numerous other features

BOM = Bill of Materials

a list of all the parts and components that make up a particular asset. Not to be confused with an Applications Parts List

Maintenance Strategy

a long-term plan, covering all aspects of maintenance management which sets the direction for maintenance management, and contains firm action plans for achieving a desired future state for the maintenance function

Emergency Maintenance Task

a maintenance task carried out in order to avert an immediate safety or environmental hazard, or to correct a failure with significant economic impact

Best Practice

a practice that is internal or external to the company or industry, that represents the best way to accomplish work

Breakdown

a specific type of failure, where an item of plant or equipment is completely unable to function

Outage

a term used in some industries (notably power generation) which is equivalent to a shutdown

Apprentice

a tradesperson (or craftsperson) in training

Tradesperson

alternative to craftsperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program

Craftsperson

alternative to tradesperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program

CBM = Condition Based Maintenance

an equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses. The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably

PM = Preventive Maintenance

an equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a fixed interval, regardless of its condition at the time

Failure

an item of equipment has suffered a failure when it is no longer capable of fulfilling one or more of its intended functions. Note that an item does not need to be completely unable to function to have suffered a failure. For example, a pump that is still operating, but is not capable of pumping the required flow rate, has failed. In Reliability Centered Maintenance terminology, a failure is often called a Functional Failure. Would you classify a planned equipment shutdown as a failure? Would you classify a routine equipment shutdown at shift change as a failure? Under this definition, the answer in the first case would be yes, but in the second case would be no. The justification for the inclusion of planned shutdowns as failures is that a failure, as defined, causes a disruption to the desired steady-state nature of the production process, and therefore should, ideally, be avoided

Maintenance

any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or to repair the equipment. Note that modifications are not maintenance, even though they may be carried out by maintenance personnel

Modification

any activity carried out on an asset which increases the capability of that asset to perform its required functions.

Planned Maintenance

any maintenance activity for which a pre-determined job procedure has been documented, for which all labor, materials, tools, and equipment required to carry out the task have been estimated, and their availability assured before commencement of the task

Unplanned Maintenance

any maintenance activity for which a pre-determined job procedure has not been documented, or for which all labor, materials, tools, and equipment required to carry out the task have been not been estimated, and their availability assured before commencement of the task

Routine Maintenance Task

any maintenance task that is performed at a regular, predefined interval

Scheduled Maintenance

any maintenance work that has been planned and included on an approved Maintenance Schedule

Maintenance Work Flow

covers all aspects of work management such as, requesting, approving, planning, scheduling, completion and documentation of maintenance activities

Average Life

how long, on average, a component will last before it suffers a failure. Commonly measured by Mean Time Between Failures

Root Cause Analysis (RCA) -

is a systematic process whereby failures are analyzed, usually by a cause and effect methodology, to determine the underlying root causes

Prescriptive maintenance

it leverages machine-learning software - artificial intelligence (AI) and the internet of things (IoT) connectivity - to help schedule preventive maintenance tasks

Schedule Compliance

one of the Key Performance Indicators often used to monitor and control maintenance. It is defined as the number of Scheduled Work Orders completed in a given time period (normally one week), divided by the total number of Scheduled Work Orders that should have been completed during that period, according to the approved Maintenance Schedule for that period. It is normally expressed as a percentage, and will always be less than or equal to 100%. The closer to 100%, the better the performance for that time period

NDT = Non-Destructive Testing

testing of equipment, which does not destroy the equipment, to detect abnormalities in physical, chemical or electrical characteristics. Techniques which are considered to be NDT techniques are ultrasonic thickness testing, dye penetrant testing, xraying, and electrical resistance testing

Shutdown

that period of time when equipment is out of service

Maintainability

the ease and speed with which any maintenance activity can be carried out on an item of equipment. May be measured by Mean Time to Repair. Is a function of equipment design, and maintenance task design (including use of appropriate tools, jigs, work platforms etc.)

Benchmarking

the process of comparing performance with other organizations, identifying comparatively high-performance organizations and learning what it is they do that allows them to achieve that high level of performance

Priority

the relative importance of a task in relation to other tasks. Used in scheduling work orders

Asset Management

the systematic planning and control of a physical resource throughout its life. This may include the asset's specification, design, and construction of the asset, its operation, maintenance, and modification while in use, and disposal when no longer required.

Downtime

the time that an item of equipment is out of service, as a result of equipment failure. The time that an item of equipment is available, but not utilized is generally not included in the calculation of downtime.

Available Hours

the total number of hours that an item of equipment is capable of performing its specified functions. It is equal to the total hours in any given period, less the downtime hours.

Asset

unlike in the accounting definition, in maintenance, this is commonly taken as any item of physical plant or equipment.

Reactive Maintenance

unplanned maintenance activities; usually performed in response to an equipment failure

Predictive maintenance

used with Computerized Maintenance Management Systems (CMMS) software. Logging work order data into a CMMS lets managers review data and notice patterns in breakdowns over time. This information enables managers to predict when downtime will occur based on historical data and schedule maintenance tasks to prevent it


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