100 Years of Maintenance and Reliability : Practical Lessons from Three Lifetimes at Process Plants

“This book is an essential tool to help pass on the wealth of knowledge of best practices to future generations of maintenance leaders. My only hope is that lots of professionals read it so that many companies and economies reap the benefits of these solid practices.”

Joel Leonard
“The Maintenance Evangelist”
MPACT Learning Center

"The book represents a great wealth of practical experience on many topics ... an essential primer on maintenance topics ... from a practical point of view. I will make this required reading by the SAMI maintenance consultants. There is certainly food for thought even for the most experienced manager."

S. Bradley Peterson
President
Strategic Asset Management, Inc.

“This is a must read for people who have to struggle with the day-to-day problems of plant life. If you have a subordinate field position in a manufacturing facility, this book will reveal why bosses do the things they do. If you are in a supervisory or management role, this book will help you steer your career.”

Charles J. Latino
CEO and President
Reliability Center, Inc.

This unique and practical book describes 42 real-life events and/or situations in the careers of the three authors from which they gained insights into the applicable best practices in maintenance and reliability. The authors explain the underlying philosophies where relevant, drawing on the teachings of the leading thinkers in leadership and management. Designed to share knowledge and experience with the readers, in a readily accessible fashion, this resource does not tell the readers what to do or how to do it; it merely explains the event or situation the authors faced, and how they dealt with it. Readers can choose whether they wish to adopt or adapt the authors’ examples. These stories are dynamic illustrations of real life situations which readers will recognize in their own work situations. With a vast potential for improvements in reliability and maintenance performance in industry, these well proven approaches and best practices are sure to help stimulate improved performance on all fronts--safety and environmental, production, maintenance costs, and reputation!

• Provides a logical organization with chapters grouped into six broad headings, enabling readers to choose the order in which they wish to absorb the lessons, which are based on the Shewhart-Deming Continuous Improvement cycle.

• In addition to the Plan-Schedule-Execute-Analyze elements, the authors have added Leadership and People to complete the suite.

• Each chapter has broadly similar sections, beginning with a Background to the events, going on to describe the key elements of the approach, and ending with Lessons and Principles.

• Underlying theories, philosophies or even detailed descriptions of methods are stripped out of the main chapters and described in Appendices, so that only those readers who wish to delve into details may do so.

• Contains a Book Summary which draws all the principles and lessons together, and gives references to the relevant chapters.

• Copiously illustrated, with charts, diagrams and tables which relate closely to the text.

Foreword by Charles J.Latino

Part 1: Introduction
Chapter 1 : Introduction & Navigation Guide
Chapter 2 : The Locations

Part 2: Leadership
Chapter 3 : Creating the vision
Chapter 4 : Setting Objectives
Chapter 5 : Changing Paradigms with Leadership and Expertise
Chapter 6 : Applying Best Business Practices
Chapter 7 : Evaluating Contractor's Unit Rates
Chapter 8 : Benchmarking

Part 3 : People
Chapter 9 : Staffing levels
Chapter 10 : Integrating Inspection and Degradation Strategies
Chapter 11 : Technician Training Challenge
Chapter 12 : Competence Profiles
Chapter 13 : Operators & Maintainers
Chapter 14 : Building a Reliability Culture
Chapter 15 : Managing Surplus Staff
Chapter 16 : Retraining Surplus Staff

Part 4 : Plan
Chapter 17 : Integrated Planning
Chapter 18 : Critical Path Planning Capability
Chapter 19 : Shutdown Management
Chapter 20 : Electrical Maintenance Strategies
Chapter 21 : Minor Maintenance by Operators
Chapter 22 : Relocating Machine Tools
Chapter 23 : Painting Contract Strategy

Part 5 : Schedule
Chapter 24 : Long Look-Ahead Plan
Chapter 25 : Workload Management
Chapter 26 : Infrastructure Maintenance
Chapter 27 : Workflow Management

Part 6 : Execute
Chapter 28 : Trip Testing
Chapter 29 : Work the Plan
Chapter 30 : Keeping to Schedule
Chapter 31 : Operators as a Maintenance Resource
Chapter 32 : Overtime Control
Chapter 33 : Managing Contractors

Part 7 : Analyze
Chapter 34 : Reliability Engineering in New Projects
Chapter 35 : Computing Reliability Data
Chapter 36 : Turnaround Performance Improvements
Chapter 37 : Reducing Shutdown Duration
Chapter 38 : A Small Matter of Cleaning
Chapter 39 : Motor Maintenance Regimes
Chapter 40 : Boiler Feed-Water Pump Seals
Chapter 41 : Cooling Water Pump Failures
Chapter 42 : Heater Outlet Flue Gas Dampers
Chapter 43 : Laboratory Oven Failures
Chapter 44 : Pump Reliability
Chapter 45 : Book Summary

Glossary
Index