Handbook of Maintenance Management and Engineering - Springer-Verlag 2009

asnt2012

Handbook of Maintenance Management and Engineering - Springer-Verlag 2009

Mohamed Ben-Daya, Prof.
Salih O. Duffuaa, Prof.
King Fahd University of Petroleum
& Minerals (KFUPM)
Department of Systems Engineering
Dhahran 31261
Saudi Arabia
bendaya@ccse.kfupm.edu.sa
duffuaa@ccse.kfupm.edu.sa
Jezdimir Knezevic, Prof.
Mirce Akademy
Longbrook Street
Exeter
Hems Mews
EX4 6AP
United Kingdom
mirce@mirce.net
Daoud Ait-Kadi, Prof.
Université Laval
Faculté de Sciences et de Génie
Département de Génie Mécanique
1314E Pavillon Adrien-Pouliot
Sainte-Foy, QC G1K 7P4
Canada
daoud.aitkadi@gmc.ulaval.ca
Abdul Raouf, Prof.Dr.
University of Management
and Technology
C-2 Johar Town
Lahore-54600
Pakistan
abdulraouf@umt.edu.pk
ISBN 978-1-84882-471-3 e-ISBN 978-1-84882-472-0
DOI 10.1007/978-1-84882-472-0
Springer Dordrecht Heidelberg London New York
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Control Number: 2009931371
© Springer-Verlag London Limited 2009

List of Contributors ...........................................................................................
Part I – Maintenance Organization
1 Maintenance Organization ................................................................................. 3
Ahmed E. Haroun and Salih O. Duffuaa
1.1 Introduction ..................................................................................................... 3
1.2 Maintenance Organization Objectives and Responsibility ............................. 5
1.3 Determinants of a Maintenance Organization ................................................. 6
1.3.1 Maintenance Capacity Planning ............................................................ 6
1.3.2 Centralization vs Decentralization ......................................................... 7
1.3.2 In-house vs Outsourcing ........................................................................ 7
1.4 Design of the Maintenance Organization ........................................................ 8
1.4.1 Current Criteria for Organizational Change ........................................... 8
1.4.2 Criteria to Assess Organizational Effectiveness .................................... 9
1.5 Basic Types of Organizational Models ........................................................... 9
1.6 Material and Spare Parts Management ......................................................... 10
1.7 Establishment of Authority and Reporting ................................................... 13
1.8 Quality of Leadership and Supervision ......................................................... 13
1.9 Incentives ...................................................................................................... 13
1.10 Education and Training ............................................................................... 14
1.11 Management and Labor Relations .............................................................. 14
1.12 Summary ..................................................................................................... 15
References ........................................................................................................... 15
2 Maintenance Productivity and Performance Measurement .......................... 17
Aditya Parida and Uday Kumar
2.1 Introduction ................................................................................................... 17
2.2 Performance Measurement and Maintenance Productivity ........................... 19
2.3 Maintenance Performance ............................................................................ 21
2.4 Measurement of Maintenance Productivity .................................................. 23

Part II – Methods and Tools in Maintenance
3 Failure Statistics ................................................................................................ 45
Mohamed Ben-Daya
3.1 Introduction ................................................................................................... 45
3.2 Introduction to Probability ............................................................................ 45
3.2.1 Sample Spaces and Events ................................................................... 45
3.2.2 Definition of Probability ...................................................................... 46
3.2.3 Probability Rules .................................................................................. 46
3.2.4 Conditional Probabilities ...................................................................... 47
3.2.5 Random Variables ................................................................................ 48
3.3 Probability Distributions ............................................................................... 49
3.4 Reliability and Failure Rate Functions .......................................................... 51
3.4.1 Introduction .......................................................................................... 51
3.4.2 Reliability Function ............................................................................. 52
3.4.3 Failure Rate Function ........................................................................... 52
3.4.4 Mean Time Between Failure (MTBF) ................................................. 53
3.5 Commonly Used Distributions ...................................................................... 54
3.5.1 The Binomial Distribution ................................................................... 54
3.5.2 The Poisson Distribution ...................................................................... 55
3.5.3 The Normal Distribution ...................................................................... 56
3.5.4 The Lognormal Distribution ................................................................ 58
3.5.5 The Exponential Distribution ............................................................... 60
3.5.6 The Weibull Distribution ..................................................................... 61
3.6 Failure Statistics ............................................................................................ 63
3.6.1 Types of Data ....................................................................................... 63
3.6.2 Parameter Estimation ........................................................................... 64
References ........................................................................................................... 73
4 Failure Mode and Effect Analysis .................................................................... 75
Mohamed Ben-Daya
4.1 Introduction ................................................................................................... 75

Part III – Maintenance Control Systems
5 Maintenance Control ......................................................................................... 93
Salih O. Duffuaa and Ahmed E. Haroun
5.1 Introduction ................................................................................................... 93
5.2 The Maintenance Control Function .............................................................. 95
5.3 The Control Process ...................................................................................... 96
5.4 Functional Structure of Maintenance Control ............................................... 97
5.5 Work Order System ...................................................................................... 99
5.5.1 Basic Documentation for Work Order System .................................... 99
5.5.2 Work Order System Flow .................................................................. 105
5.6 Tools Necessary for Effective Maintenance Control System ..................... 107
5.6.1 Work Control ..................................................................................... 108
5.6.2 Cost Control ....................................................................................... 109
5.6.3 Quality Control .................................................................................. 109
5.6.4 Plant Condition Control ..................................................................... 109
5.7 Effective Programs for Improving Maintenance Control ............................ 110
5.7.1 Emergency Maintenance .................................................................... 110
5.7.2 Reliability Improvement .................................................................... 110
5.7.3 Total Productive Maintenance ........................................................... 111
5.7.4 Computerized Maintenance Management and Information
Technology ................................................................................................. 111
5.8 Summary ..................................................................................................... 112
References ......................................................................................................... 112
6 Guidelines for Budgeting and Costing Planned Maintenance Services ...... 115
Mohamed Ali Mirghani
6.1 Introduction ................................................................................................. 115
6.2 An Overview of Budgeting and Costing Systems ....................................... 116

7 Simulation Based Approaches for Maintenance Strategies Optimization .. 133
Fouad Riane, Olivier Roux, Olivier Basile, and Pierre Dehombreux
7.1 Introduction ................................................................................................. 133
7.2 Reliability Models Estimation .................................................................... 134
7.2.1 Regression and ML Methods ............................................................. 134
7.2.2 Uncertainty Affecting Reliability Model .......................................... 136
7.3 Maintenance Performance .......................................................................... 138
7.3.1 Availability Model ............................................................................. 138
7.3.2 Costs Model ....................................................................................... 139
7.4 Simulation Based Maintenance Framework ............................................... 141
7.4.1 Toward a Unified Framework ............................................................ 141
7.4.2 Maintenance Strategies ...................................................................... 142
7.4.3 Uncertainty Affecting Maintenance Performances ............................ 146
7.5 A Case Study .............................................................................................. 148
7.6 Conclusion .................................................................................................. 152
References ......................................................................................................... 152
Part IV – Maintenance Planning and Scheduling
8 Maintenance Forecasting and Capacity Planning ........................................ 157
Hesham K. Alfares and Salih O. Duffuaa
8.1 Introduction ................................................................................................. 157
8.2 Forecasting Basics ...................................................................................... 158

26 Human Error in Maintenance – A Design Perspective .............................. 711
Clive Nicholas
26.1 Introduction ............................................................................................... 711
26.2 Human Error in Aircraft Maintenance ...................................................... 712
26.3 Significance of Maintenance Error ........................................................... 713
26.4 Design Impact .......................................................................................... 717
26.5 Analysis Required for Design Solutions .................................................. 718
26.5.1 Maintenance Tasks ........................................................................... 721
26.5.2 Maintenance Errors .......................................................................... 722
26.5.3 Causal Factors .................................................................................. 724
26.6 Design Strategies and Principles ............................................................... 726
26.6.1 Appreciate the Maintainer’s Perspective of the Aircraft ................. 729
26.6.2 Design for the Aircraft Maintenance Environment ......................... 729
26.6.3 Protect the Aircraft and Protect the Maintainer............................... 731
26.6.4 Avoid Complexity of Maintenance Tasks ....................................... 732
26.6.5 Enable Adequate Maintenance Access ........................................... 732
26.6.6 Positively Standardise and Positively Differentiate ........................ 733
26.6.7 Build Error Detection into the Maintenance Process ....................... 734
26.7 Conclusion ................................................................................................ 734
References ......................................................................................................... 735
Index..................................................................................................................... 737

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