From the Publisher

10th Discipline on Reliability and Continuous Improvement

All books written are based on each of the disciplines on World Class Maintenance Management. This book on Maintenance Roadmap to Reliability is included in the tenth discipline on Reliability and Continuous Improvement.

Maintenance - Roadmap to Reliability Book

Phase 1: The goal of Phase 1 is for the maintenance team to establish the Basic Equipment Condition hand in hand in their equipment is to transition from a stage where accelerated deterioration is rampant to a stage of natural deterioration for parts which are age-related in nature where they tend to reach its natural lifespan.

Phase 2: The challenge in this phase is for maintenance to addressing design Weaknesses by lengthening equipment lifetime. Once Phase 1 restoration has been completed and accelerated deterioration has been reduced, there are parts of the equipment that will wear out and suffer from natural deterioration, which means that the part has reached its natural lifespan. The team will expose and analyze several parts of the equipment with short lifespan and challenge themselves to improve upon it.

Phase 3 is about creating a sustaining process so that the equipment basic condition can be preserved and maintain. Since the Planned Maintenance team have exerted a great effort on restoring and and addressing design problems, we do not want the equipment to revert back to its previous state of being neglected. We can also integrate the process of RCM on this Planned Maintenance Phase.

Phase 4: The last Phase on Planned Maintenance is about Predictive Equipment Lifetime. In this phase, we now introduce the concept of Predictive Maintenance or Condition-Based monitoring techniques, although this is similar to using the human senses in a much higher perspective with the aid of sophisticated precision instruments. Several parts of the equipment can be predicted through the use of these specialized diagnostic instruments.

Maintenance, Roadmap to Reliability is the second of the series of books on World Class Maintenance that details the TPM pillar on Planned Maintenance. While Autonomous Maintenance can be considered the most popular pillar of TPM, my experience tells me that Planned Maintenance should be the strongest pillar of TPM. Why? If the structure of Planned Maintenance is weak then Autonomous Maintenance will stall.

Every industry plans on achieving a level of Every industry plans on achieving a level of World Class Maintenance and the challenge is how to begin this journey. This book is specifically written for that purpose. While there may be different strategies to do this and many will revert to automation and the application of Condition-Based Maintenance. This book simply explains that the very first step is to go back to the basics. One of the most important aspects is creating a solid partnership with operators.

It is not only the maintenance that should understand their role in the equipment, but the entire organization itself must also understand that indirectly they greatly contribute to problems on why maintenance is reactive. Industries that value their people provide a better chance of changing their culture rather than industries that keep on changing people because they think that people are expendable. Changing culture, especially for the maintenance function, will never work if industries keep on changing their people.

Maintenance - Roadmap to Reliability Book

This book provides maintenance people in industries a detailed and step by step guide on how to successfully implement the TPM Pillar on Planned Maintenance through the 4 phases. Following these guidelines will definitely reduce unplanned breakdowns and failures in equipment and assets.