Front Cover -- Rules of Thumb for Maintenance and Reliability Engineers -- Copyright Page -- Dedication Page -- Contents -- Introduction-The Recommended First Step to Rules of Thumb in Reliability Engineering -- Part I: The Basics of Maintenance and Reliability -- Chapter 1: Understanding Maintenance and Reliability -- 1.1. The Maintenance Function -- 1.2. Strategy to Achieve World-Class Production through Reliability -- 1.2.1. Maintenance Approaches -- 1.2.2. Maintenance Management Philosophy -- 1.2.3. The Function and Control System -- 1.2.4. What Is Maintenance? -- 1.2.5. Specification -- 1.2.6. The Maintenance Function -- 1.3. What Is Reliability? -- 1.3.1. Companies That Get It -- 1.3.2. Why Move Toward Proactive Work? -- 1.3.3. A New Way to View Failure -- 1.4. Maintenance/Reliability Assessment -- 1.5. Introduction to Change Management -- 1.6. Developing a Business Case for a Reliability Initiative -- 1.7. Calculating Return on Investment -- 1.7.1. Leadership of the ROI Team -- 1.7.2. Case Study -- 1.8. Planning and Scheduling -- Chapter 2: The Functional Maintenance Organization and Its People -- 2.1. Functional Maintenance Organizational Structure -- 2.2. Maintenance Supervisor -- 2.2.1. Responsibilities -- 2.2.2. Environmental, Health, and Safety Aspects -- 2.3. Maintenance Planner/Scheduler -- 2.3.1. Responsibilities -- 2.4. Maintenance and Engineering Manager -- 2.4.1. Responsibilities -- 2.4.2. Environmental, Health, and Safety Aspects -- 2.5. Area Manager of Warehouse and Inventory Control -- 2.5.1. Responsibilities -- 2.6. Reliability Engineer -- 2.6.1. Responsibilities -- 2.6.2. Job Skills -- 2.6.3. Reliability Engineering Dashboard-Key Performance Indicators -- Chapter 3: Preventive Maintenance Program -- 3.1. Reliability-Based Preventive Maintenance -- 3.1.1. Information Collection -- 3.1.2. System Analysis.

3.1.3. Identification of Systems -- 3.1.4. Identification of System Functions -- 3.1.5. Selection of Systems -- 3.1.6. System Functional Failure and Criticality Rating -- 3.2. Identification of Functionally Significant Items -- 3.3. Maintenance Task Selection (Decision Logic Tree Analysis) -- 3.3.1. Levels of Analysis -- 3.3.2. Paralleling and Default Logic -- 3.4. Maintenance Tasks -- 3.5. Task Frequencies/Intervals -- Chapter 4: Predicitive Maintenance Program -- 4.1. Setting Up a Preventive/Predictive Maintenance Program -- 4.2. Visual Inspection -- 4.3. Vibration Analysis -- 4.4. Thermography -- 4.5. Tribology -- 4.6. Ultrasonics -- Chapter 5: Reliability Processes -- 5.1. Reliability Software-Managing the Health of Assets -- 5.1.1. Building an Effective Asset Reliability Program -- 5.1.2. Using Reliability Software to Put the Program into Action -- 5.1.3. Using Handheld Devices to Collect and Upload Condition Inspection Data -- 5.1.4. Plotting Asset Health Trends -- 5.1.5. Capturing the Experts' Knowledge about Asset Condition -- 5.1.6. Integration to Enterprise Asset Management and Computerized Maintenance Management Systems -- 5.1.7. The Bottom Line -- 5.2. Seven Questions Addressed by Reliability Centered Maintenance -- 5.3. Failure Mode and Effects Analysis -- 5.4. Equipment Criticality Analysis -- 5.4.1. Preparing for an Equipment Criticality Analysis -- 5.4.2. Conducting the Review -- 5.4.3. Analyzing the Assessment Results -- 5.4.4. Using the Output of the Equipment Criticality Assessment -- 5.4.5. Conclusions -- 5.5. Root Cause Analysis -- 5.5.1. Plan -- 5.5.2. Do -- 5.5.3. Check -- 5.5.4. Act -- Chapter 6: Key Performance Indicators -- 6.1. Defining and Understanding KPIs -- 6.1.1. The Problem -- 6.1.2. John Day -- 6.1.3. The Solution -- 6.2. KPI Dashboards -- 6.2.1. Plant Manager Dashboard -- 6.2.2. Plant Management Team Dashboard.

6.2.3. Production Manager (Supervisor) Dashboard -- 6.2.4. Production Operator Dashboard -- 6.2.5. Maintenance Manager (Supervisor) Dashboard -- 6.2.6. Maintenance Staff Dashboard -- 6.2.7. Reliability Engineer Dashboard -- 6.2.8. Engineering Manager Dashboard -- 6.2.9. Purchasing Manager Dashboard -- 6.2.10. Maintenance Stores Manager -- 6.2.11. Conclusion -- 6.3. Measuring and Managing the Maintenance Function -- 6.3.1. Physical Asset Management -- 6.3.2. The Asset Reliability Process -- 6.3.3. Performance Metrics for the Maintenance Function -- 6.3.4. Reliability Process Key Performance Indicators-Leading Measures -- 6.3.5. Work Identification -- 6.3.6. Work Planning -- 6.3.7. Work Scheduling -- 6.3.8. Work Execution -- 6.3.9. Follow-Up -- 6.3.10. Performance Analysis -- 6.3.11. Key Performance Indicators of Maintenance Effectiveness (Result Measures) -- 6.3.12. The Importance of the Work Order -- 6.3.13. Reporting and Use of Key Performance Indicators -- 6.3.14. Conclusion -- Chapter 7: Total Productive Maintenance -- 7.1. Introduction to Total Productive Maintenance -- 7.1.1. The TPM Organization -- 7.1.2. TPM Objectives -- 7.1.3. Autonomous Maintenance -- 7.1.4. Equipment Management -- 7.1.5. TPM Integration -- 7.1.6. TPM Is an Investment -- 7.1.7. Calculating Major Losses Is Key to TPM's Success -- 7.2. Lean Reliability -- 7.2.1. The Evolution from Lean Manufacturing to Lean Maintenance to Lean Reliability -- 7.2.2. Managing Asset Performance to Meet Customer Needs -- 7.2.3. The Basic Principles of Lean Reliability -- 7.2.4. How Lean Reliability Aligns with TPM, Kaizen, Five S, and Six Sigma -- 7.2.5. Key Elements to Implement and Sustain Lean Realiability -- 7.2.6. Summary -- Part II: Equipment and Processes -- Chapter 8: Chain Drives -- 8.1. Chain Selection -- 8.1.1. Plain or Detachable-Link Chain -- 8.1.2. Roller Chain -- 8.1.3. Sprockets.

8.2. Chain Installation -- 8.3. Power Train Formulas -- 8.3.1. Shaft Speed -- 8.4. Chain Length -- 8.5. Multiple Sprockets -- 8.6. Chain Speed -- 8.7. Preventive Maintenance Procedures -- Chapter 9: Hydraulics -- 9.1. Hydraulic Knowledge -- 9.2. Hydraulic Troubleshooter -- 9.3. General Maintenance Person -- 9.4. Best Maintenance Hydraulic Repair Practices -- 9.5. Root Cause Failure Analysis -- 9.6. Preventive Maintenance -- 9.7. Measuring Success -- 9.8. Recommended Maintenance Modifications -- Chapter 10: Maintenance Welding -- 10.1. Shielded Metal Arc Welding (SMAW), "Stick Welding" -- 10.2. Flux-Cored Arc Welding (FCAW) -- 10.2.1. FCAW with Gas -- 10.2.2. FCAW Self-Shielded -- 10.3. Gas-Shielded Metal Arc Welding (GMAW) -- 10.3.1. GMAW for Maintenance Welding -- 10.3.2. Gas Selection for GMAW -- 10.4. Gas Tungsten Arc Welding (GTAW) -- 10.4.1. Applicability of GTAW -- 10.4.2. Advantages and Disadvantages of GTAW -- 10.4.3. Principles of Operating GTAW -- 10.4.4. Polarity and GTAW -- 10.4.5. GTAW Shielding Gases and Flow Rates -- 10.4.6. Electrode Material for GTAW -- 10.4.7. GTAW Electrode Size and Tip Shape -- 10.4.8. GTAW Electrode Holders and Gas Nozzles -- 10.4.9. Characteristics of GTAW Power Supplies -- 10.4.10. GTAW Torches -- 10.4.11. Manual GTAW Techniques -- 10.4.12. Establishing Welding Parameters for GTAW -- 10.4.13. Gas Tungsten Arc Starting Methods -- 10.5. Oxyacetylene Cutting -- 10.6. Air-Carbon Arc Cutting and Gouging -- 10.6.1. Applications -- 10.6.2. Power Sources -- 10.7. Plasma Arc Cutting -- 10.8. Welding Procedures -- 10.9. Qualification of Welders -- 10.10. Plasma Arc Welding -- 10.11. Base Metals -- 10.11.1. The Carbon Steels -- 10.11.2. The Alloy Steels -- 10.11.3. The Nonferrous Metals -- 10.12. Control of Distortion -- 10.13. Special Applications -- 10.13.1. Sheet Metal Welding -- 10.13.2. Hard Surfacing.

10.13.3. Resisting Abrasive Wear -- 10.13.4. Resisting Impact Wear -- 10.13.5. Types of Surfacing Electrodes -- 10.13.6. Choosing Hard-Facing Material -- 10.13.7. Check Welding Procedure -- 10.13.8. Check Before the Part Is Completely Worn -- 10.13.9. Hard Surfacing with SAW -- 10.14. Selection and Maintenance of Equipment -- 10.14.1. Machines -- 10.14.2. Accessory Equipment -- 10.15. Installation of Equipment -- 10.16. Equipment Operation and Maintenance -- 10.16.1. Keep the Machine Clean and Cool -- 10.16.2. Do Not Abuse the Machine -- 10.16.3. Do Not Work the Machine Over Its Rated Capacity -- 10.16.4. Do Not Handle Roughly -- 10.16.5. Maintain the Machine Regularly -- 10.17. Safety -- Chapter 11: Bearings -- 11.1. Types of Movement -- 11.1.1. About a Point (Rotational) -- 11.1.2. About a Line (Rotational) -- 11.1.3. Along a Line (Translational) -- 11.1.4. In a Plane (Rotational/Translational) -- 11.2. Commonly Used Bearing Types -- 11.2.1. Plain Bearings -- 11.2.2. Rolling Element or Antifriction -- 11.2.3. Roller -- 11.3. Bearing Materials -- 11.3.1. Plain -- 11.3.2. Rolling Element -- 11.4. Lubrication -- 11.4.1. Plain Bearings -- 11.4.2. Rolling Element Bearings -- 11.5. Installation and General Handling Precautions -- 11.5.1. Plain Bearing Installation -- 11.5.2. Roller Bearing Installation -- 11.5.3. General Roller-Element Bearing Handling Precautions -- 11.6. Bearing Failures, Deficiencies, and Their Causes -- 11.6.1. Improper Bearing Selection and/or Installations -- Chapter 12: Compressors -- 12.1. Centrifugal -- 12.1.1. Configuration -- 12.2. Performance -- 12.2.1. First Law of Thermodynamics -- 12.2.2. Second Law of Thermodynamics -- 12.2.3. Pressure/Volume/Temperature (PVT) Relationship -- 12.2.4. Pressure/Compression -- 12.2.5. Other Performance Indicators -- 12.3. Positive Displacement -- 12.3.1. Rotary -- 12.4. Reciprocating.

12.4.1. Configuration.