Complete Guide to Preventive and Predictive Maintenance, 2nd Edition


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Complete Guide to Preventive and Predictive Maintenance, 2nd Edition

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Complete Guide to Preventive and Predictive Maintenance, 2nd Edition

 

Joel Levitt

 

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Complete Guide to Predictive and Preventive Maintenance, 2nd Edition is a best-selling and thoroughly revised reference. It shares the best practices, victories, essential steps for success, and yes, the mistakes, which Joel Levitt has gleaned from working with countless organizations over a 30-year period.

 

It is the first book to address all four elements essential for success in preventive maintenance systems - engineering; economics; psychological (people); and management - thereby enabling all who use it to have a balanced understanding of what is happening their organizations. Complete Guide to Preventive and Predictive Maintenance, 2nd Edition blends concrete actionable steps and structures with the underlying theory.

 

The author has included check sheets, sample task lists, protocols for analysis, as well as stories and case histories. This complete guide will be a practical and invaluable on-the-job resource for maintenance managers, engineers, planners, supervisors, PM group leaders and PM mechanics.

 

Features

  • Includes added chapters on PM for shutdowns.
  • Contains material on how to understand and avoid iatrogenic failure (failures caused by servicing).
  • Features a greatly expanded discussion of the concept of the P/F curve and how to make it a more useful tool.
  • Provides information on how to explain and sell Proactive Maintenance to management.
  • Includes check sheets, history of PM, stories, photographs, and case histories.
  • Contains a glossary of terms.
  • Provides sample task lists for a variety of equipment with some of the logic behind each task.
  • Offers templates for developing your own tasking.
  • Includes protocols for detailed economic analysis with examples.

Complete Guide to Predictive and Preventive Maintenance, 2nd Edition

by Joel Levitt

 

Joel Levitt

Joel Levitt is a leading trainer of maintenance professionals. He has trained more than 15,000 maintenance leaders from 3000 organizations in 20+ countries in over 500 sessions. Since 1980 he has been the President of Springfield Resources, a management consulting firm that services clients of all sizes on a wide range of maintenance issues.


He has 25 years of experience in many facets of maintenance including process control design, source equipment inspector, electrician, field service technician, maritime operations and property management. Prior to that, Levitt worked for a CMMS vendor and as an owner/manager in manufacturing.


He is a frequent speaker at maintenance and engineering conferences and has written 10 popular maintenance management texts. He has also published over 6 dozen articles on the topic. Levitt has served on the safety board of ANSI, Small Business United, National Family Business Council and on the executive committee of the Miquon School. He is a member of AFE and Vice President of the Philadelphia chapter.

 

Learn more about Joel and his company, Springfield Resources, here.

Complete Guide to Predictive and Preventive Maintenance, 2nd Edition

by Joel Levitt

 

Chapter 1 The Goal of Maintenance


Proactive Maintenance (PrM)


The Goal of maintenance is (paradoxically) to get out of the maintenance business. Your job will become clear when you understand this! That is the function of the proactive budget.

Figure 1.4 illustrates three ways to manage physical assets. The x-axis represents time or utilization. As you travel to the right more time has elapsed, more product has been made, or more mileage has been driven.

The y-axis represents the number of breakdowns or disruptive incidents. The more breakdowns that occur, the higher the curve. Eventually everything wears out. The plant’s first breakdown is on the left side of the curve, just where the curve becomes visible. Similarly, the last breakdown in that plant is on the right side of the curve, where it intersects the x-axis.

Each scenario reflects the average life of all equipment in the facility under that program. For example, if you operate a fleet of cars and don’t do any maintenance, the cars will have a certain average breakdown rate. If you add PM activity, the average life will be extended. In the last curve to the right, you re-engineer the cars to be more reliable. Every time you get some breakdowns you look for designs that are more reliable and further modify the equipment.




 
Figure 1.4 illustrates three ways to manage physical assets like your factory, facility, or fleet.You can let it break, you can PM it including TLC and inspection, or you can be proactive and find the causes of the failures and eliminate them

Complete Guide to Predictive and Preventive Maintenance, 2nd Edition

by Joel Levitt

 

Dedication


This work is dedicated to my personal maintenance consultant Hall of Fame. These people taught me much of what I know about maintenance consulting. They also represent integrity, quality, and good value for their clients.


These people worked (or are working) behind the scenes to make our field more robust, dignified, knowable, and useful. Semond Levitt, my father, was the prototypical consultant interested about any topic that came in to his attention. Jay Butler was my first consultant employer and had his own unique beliefs about fleet maintenance, many of which I now share. Don Nyman, who is both a colleague and my collaborator on a book on planning, trained me when I started in the field. Ed Feldman trained and advised me on custodial maintenance. Ricky Smith and Richard Jamison generously let me work with their consultants on larger projects and gave me insight into larger maintenance consultancies. Mark Goldstein has been an indefatigable friend—a mentor and teacher with a unique insight into the best role for maintenance. Mike Brown and his wife Tessa Marquis have contributed to me personally and to many aspects of the profession from courses and computer-based training.


Another group has affected me because of their presence in the field. Some are my friends too. Terry O’Hanlon is one of the anchors of the whole field and leads the charge online. John Carleo has mentored and nurtured a whole bunch of maintenance management writers (myself included). One in his stable of writers is Terry Wireman, who has written extensively about all aspects of maintenance. Tom Wingenter has been the champion of the Maintenance Certificate program at the University of Alabama for 20 years.


From Down Under, Bill Holmes and the SIRF RT Facilitators do a remarkable job in keeping their members up to date. Philip Slater, Steve Turner, and Sandy Dunn have made Australia the thought leader in the field.


Then there are some young’uns like Darrell Mather, the Linked-In thought leader (who may be anywhere) and author/consultant, and Joel Leonard, the maintenance crisis song guy.


Finally Peter Todd of SIRF provided a wealth of information for the PdM sections. I’m sure there are more people who are in this role that don’t come to mind immediately. This work is dedicated to them too….



Joel Levitt

Complete Guide to Predictive and Preventive Maintenance, 2nd Edition

by Joel Levitt

 

  • The Goal of Maintenance
  • Selling PPM to Management: Battle for a Share of the Mind
  • P/PM Economics
  • Groundwork
  • PM Basics
  • PM Details for Effectiveness
  • Simple Statistics and PM Frequency
  • TPM (Total Productive Maintenance)
  • Iatrogenic Failure
  • Advanced Concepts-PM at the Next Level
  • Predictive Maintenance
  • Chemical and Particle Analysis Predictive Tasks
  • Mechanical Predictive Tasks
  • Energy Related Tasks
  • CMMS Approaches to PM and PdM
  • Management of PM Activity
  • Using Metrics or KPIs to Manage PM and PdM
  • Outsourcing PM
  • Short Repairs and High Productivity
  • Psychological and Personnel Issues
  • Special Case: PM in Shutdowns and Outages
  • Reliability Enhancement Programs
  • Task List Development
  • Task List Analysis
  • Debugging your PM Program
  • Get it Going Right
  • The Future of P/PM
  • Appendix A: Glossary of Maintenance Management Terms
  • Appendix B: Resources
  • Appendix C: Task List Library
  • Index