Benjamin W. Niebel - Engineering Maintenance Management (Industrial Engineering)

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INDUSTRIAL ENGINEERING

A Series of Reference Books and Textbooks

1. Optimization Algorithms for Networks and Graphs, Edward Minieka

2. Operations Research Support Methodology, edited by Albert G. Holzman

3. MOST Work Measurement Systems, Kjell B. Zandin

4. Optimization of Systems Reliability, Frank A. Tillman, Ching-Lai Hwang, and Way Kuo

5. Managing Work-In-Process Inventory, Kenneth Kivenko

6. Mathematical Programming for Operations Researchers and Computer Scientists, edited by Albert G. Holzman

7. Practical Quality Management in the Chemical Process Industry, Morton E. Bader

8. Quality Assurance in Research and Development, George W. Roberts

9. Computer-Aided Facilities Planning, H. Lee Hales

10. Quality Control, Reliability, and Engineering Design, Balbir S. Dhillon

11. Engineering Maintenance Management, Benjamin W. Niebel

12. Manufacturing Planning: Key to Improving Industrial Productivity, Kelvin F. Cross

13. Microcomputer-Aided Maintenance Management, Kishan Bagadia

14. Integrating Productivity and Quality Management, Johnson Aimie Edosomwan

15. Materials Handling, Robert M. Eastman

16. In-Process Quality Control for Manufacturing, William E. Barkman

17. MOST Work Measurement Systems: Second Edition, Revised and Expanded, Kjell B. Zandin

18. Engineering Maintenance Management: Second Edition, Revised and Expanded, Benjamin W. Niebel

Additional Volumes in Preparation

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Engineering Maintenance Management

Second Edition,
Revised and Expanded

Benjamin W. Niebel

Professor Emeritus of Industrial Engineering
The Pennsylvania State University
University Park, Pennsylvania

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Library of Congress Cataloging-in-Publication Data

Niebel, Benjamin W.
Engineering maintenance management / Benjamin W. Niebel.2nd ed., revised
and expanded.
p. cm. (Industrial engineering; 18)
Includes bibliographical references and index.
ISBN 0-8247-9247-5
1. Plant maintenanceManagement. I. Title. II. Series.
TS192.N54 1994
658.202dc20 9416961
CIP

The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/Professional Marketing at the address below.

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Copyright 1994 by Marcel Dekker, Inc. All Rights Reserved.

Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher.

Marcel Dekker, Inc.
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Current printing (last digit):
10 9 8 7 6 5 4 3 2 1

PRINTED IN THE UNITED STATES OF AMERICA

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The continuing effort by industries to be internationally competitive necessitates that industrial and business management become more cost-effective in the operation of all facets of an enterprise. Maintenance is an important area that has not been studied with the same intensity as, for example, production. Consequently, the maintenance effort in most companies can be improved significantly from the standpoints of quality, cost, and time of delivery.

Modernization has taken place in almost all industries and businesses. The installation of more flexible computer-controlled automatic equipment is commonplace. Also, in recent years, there has been an ever-increasing effort in the utilization of advanced mechanized material-handling equipment. With this modernization, the complexity and amount of maintenance have increased. It is not uncommon today to have the cost of maintenance exceed the cost of direct labor.

Because of this continuing increase in the importance of maintenance, the second edition of Engineering Maintenance Management has been written with the same objective as the first, that is, to provide practical assistance to the various levels of maintenance management. The first edition has been thoroughly tested by diverse industries throughout the world. It has been the basis of seminars and short courses offered not only in the United States but

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in Japan, South Korea, Singapore, Malaysia, Mexico, and China. The second edition should prove to be more beneficial to all those associated with maintenancefrom the maintenance craft foreman to the chief plant engineer.

The second edition covers the fundamental theories, principles, procedures, and techniques utilized by engineering maintenance management. Throughout the book, proven techniques for providing more cost-effective maintenance are emphasized. It includes numerous illustrations, tables, charts, and forms valuable for establishing or improving procedures.

This edition contains new chapters on utilities management, plant rearrangement and minor construction, subcontracted maintenance services, fire protection, and controlling residual waste and contaminated storm water discharge. These materials have been added at the suggestion of the many users of this book. In addition, the chapter on designing for reliability has been expanded to include system effectiveness. This chapteralong with the chapters on preventive maintenance, diagnostic techniques, and computerized maintenanceprovides the essentials for optimizing the maintenance function.

Beginning with the functional design of a new product and continuing to the identification of failure systems that permit planned maintenance, this book provides product and plant engineers with practical methods of developing more reliable products and systems that can be well maintained in a cost-effective manner. Application of the computer to provide more timely and thorough information for maintenance management control is emphasized. In addition, the how and why of maintenance management are covered thoroughly. There are up-to-date presentations on the maintenance organization, maintenance cost and control systems, estimating material and labor costs, inventory control of maintenance materials including economic order quantities, and maintenance planning and scheduling. Other chapters cover preventive and predictive maintenance and the utilization of diagnostic techniques. Substantive discussions are also presented in the areas of pre-employment testing of maintenance employees, training for maintenance work and engineering maintenance management work, measuring maintenance performance, determining compensation for maintenance work, and improving maintenance performance.