Productivity and Reliability-Based Maintenance Managementis intended to provide a strong yet practical foundation for understanding the concepts and practices of total productive maintenance (TPM) management--a proactive asset and resource management strategy that is based on enhancing equipment reliability and overall enterprise productivity. The book is intended to serve as a fundamental yet comprehensive educational and practical guide for departing from the wait-failure-emergency repair cycle that has plagued too many industries and advancing to a proactive and productive maintenance strategy. It is not intended to be a how-to-fix-it manual but instead emphasizes the concept of a world-class maintenance management philosophy to avoid the failure in the first place. This book serves to fill an immense void in the instructional needs of technology students at all levels. Universities, junior and community colleges, and technical institutes as well as professional, corporate, and industrial training programs can benefit by incorporating these fundamental concepts in their technical and managerial curricula. It can serve as a powerful educational tool for students as well as for maintenance professionals and managers. In Chapter 1, various types of maintenance organizations and practices are defined and discussed. Through a realistic cost-and-benefit approach, the book introduces the reader to the basic concepts of productivity through proactive maintenance management practices.

The introductory chapter is followed by a discussion of equipment life expectancy, expected failure rates, and the general concepts of reliability in Chapter 2. Basic statistical models and distributions necessary for understanding reliability issues also are discussed. The author embraces the philosophy that concepts, simple or complex, are best appreciated by the reader when they are presented in a clear and easy-to-understand manner. Therefore, all mathematical presentations are reduced to the simplest form. Chapters 3 and 4 provide a clear presentation of state-of-the-art yet practical preventive and predictive techniques and applications, followed by an in-depth discussion of nondestructive testing and evaluation techniques as they are applicable to maintenance management strategies in Chapter 5. Practical steps for determining current equipment effectiveness and real-world guidelines and examples for implementation of TPM are presented in Chapters 6 and 7. Strong emphasis is placed on operator and employee education, empowerment, and ownership of equipment and processes. Other important and relevant failure prevention and productivity improvement topics such as benchmarking; cause and effect, root cause analysis; fault tree; and failure mode and effect analysis (FMEA) are presented in Chapter 7.

Clear emphasis is placed on the applicability of these tools in the maintenance arena. Chapter 8 takes a practical look at maintenance project management, and the application of various tools is explained. CMMS (computer maintenance management systems) and its role in modern maintenance management are introduced in Chapter 9. Relevant and real-world case studies are used in most chapters in the Case in Point features, in order to highlight the importance of sound and proactive maintenance practices. End-of-chapter questions summarize and solidify the concepts that are presented in each chapter.