Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM), 1st Edition (Hardback) book cover

Equipment Management in the Post-Maintenance Era

A New Alternative to Total Productive Maintenance (TPM), 1st Edition

By Kern Peng

Productivity Press

255 pages | 22 B/W Illus.

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pub: 2012-04-12
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Description

Recent advancements in information systems and computer technology have led to developments in equipment and robotic technology that have permanently changed the characteristics of manufacturing equipment. Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM) introduces a new way of thinking to help high-tech organizations manage an increasingly complex equipment base. It also facilitates the fundamental understanding of equipment management those in traditional industries will need to prepare for the emerging microchip era in equipment.

Kern Peng shares insights gained through decades of managing equipment performance. Using a systems model to analyze equipment management, he introduces alternatives in equipment management that are currently gaining momentum in high-tech industries. The book highlights the fundamental internal flaw in maintenance organizational setup, presents new approaches to replace maintenance functional setup, and illustrates a time-tested transformation and implementation process to help transition your organization from the maintenance era to the new post-maintenance era.

  • Breaks down the history of equipment into five phases
  • Provides a clear understanding of equipment management fundamentals
  • Introduces alternatives in equipment management beyond the mainstream principles of maintenance management

The book examines maintenance management logistics, including planning and budgeting, training and people development, customer services and management, vendor management, and inventory management. Supplying a comprehensive look at the history of equipment management, it analyzes current maintenance practice and details approaches that can significantly improve the effectiveness and efficiency of your equipment management well into the future.

Reviews

If you are at all responsible for equipment management, especially in high tech, you need to read this book. And give it to your boss. Dr. Peng has illustrated in great detail why equipment maintenance should no longer be considered a standalone function but rather a strategic competitive opportunity that impacts all facets of the organization.

—Kurt A. Beiter, PhD., Dept. of Mechanical Engineering, Stanford University

This book points out, in substantial clarity, that while numerous concepts have been adopted and applied over the years (such as TPM, Predictive Maintenance, etc.) they fall short of meeting the significant challenges of the future–especially in the world of hi-tech, complex equipment … an absolutely superb account of the history of equipment maintenance and the progression of new advances that have taken place over the past few decades.

—John W. Davis, author of Progressive Kaizen: Leading the Lean Initiative, and Fast Track to Waste-Free Manufacturing

Table of Contents

INTRODUCTION TO EQUIPMENT MANAGEMENT

Introduction

Background

Maintenance Management

Equipment Management

Key Equipment Terminology

Equipment States

Equipment Time

Equipment Actions

Equipment Failure Patterns

Equipment Performance Measurements

History of Equipment Management

Introduction

Phase 1: Breakdown Management

Phase 2: Preventive Maintenance

Phase 3: Productive Maintenance

Phase 4: Total Productive Maintenance

Phase 5: TPM with Predictive Maintenance

Summary of the Pre-maintenance and Maintenance Phases

Introduction to the Post-Maintenance Era

The New Business Environment

Operational Changes

Equipment Characteristics

New Enabling Technologies

New Management Concepts

The Issues of Maintenance

Problems in Objectives

Structural Inefficiency

Unsuitable for Changing Environment

Introduction to Phase 6: Post-Maintenance Era

THE MAINTENANCE SYSTEM

General Maintenance Concepts and Practices

Introduction

Preventive Maintenance

Preventive Maintenance Schedule

Preventive Maintenance Task List

Preventive Maintenance Staffing Requirements

Preventive Maintenance Equipment/Tool Requirements

Preventive Maintenance Materials/Parts Requirements

Preventive Maintenance Information System

Reliability-Centered Maintenance

Predictive Maintenance

Maintenance Prevention

Total Productive Maintenance

Terotechnology

Maintenance Management Logistics

Introduction

Planning and Budgeting

Strategic Planning in Maintenance

Headcount Plan

Budget Plan

Tactical Planning in Maintenance

Training and People Development

Customer Services and Management

Vendor, Supplier, and Contract Management

Inventory Management

Maintenance Performance Indicators

Introduction

Equipment Performance Indicators

Safety Indicators

Purpose

Format and Variation

Presentation

Availability Indicators

Purpose

Format and Variation

Presentation

Reliability Indicators

Purpose

Format and Variation

Presentation

Maintainability Indicators

Purpose

Format and Variation

Presentation

Utilization Indicators

Purpose

Format and Variation

Presentation

Process Performance Indicators

Labor Productivity Indicators

Purpose

Format and Variation

Presentation

Nonproductive Downtime Indicators

Purpose

Format and Variation

Presentation

Customer Satisfaction Indicators

Purpose

Format and Variation

Presentation

Operational Misses and Error Rates

Purpose

Format and Variation

Presentation

Cost Performance Indicators

Cost Rates

Purpose

Format and Variation

Presentation

Cost Breakdown by Categories

Purpose

Format and Variation

Presentation

Computerized Maintenance Management Systems

Introduction

CMMS Objectives

CMMS Functions

Equipment Module

Work Order Module

Preventive Maintenance Module

Safety Module

Labor Module

Inventory Module

Financial Module

Calendar Module

CMMS Features

Assessibility and Security

Communication and Notification

Data Entry and Presentation

Integration

Flexibility and Customization

CMMS Implementation

THE POST-MAINTENANCE ERA

The Systems View of the Equipment Management Process

Introduction

Environmental Suprasystem

Goals and Values Subsystem

Structural Subsystem

Technical Subsystem

Psychosocial Subsystem

Managerial Subsystem

New Changes in the Post-Maintenance Era

Introduction

Equipment Management Objectives

Functional-Level Objectives

Job-Level Objectives

Organizational Structure Changes

The Platform Ownership Concept

Employee Skill Requirements

Computerized Equipment Management Systems

Work Environment Changes

Management Changes

Summarizing the Post-Maintenance Era

Transformation and Implementation

Introduction

Environmental Studies

Managerial Preparedness

Goal and Value Changes

Psychosocial Changes

Technical Changes

Structural Changes

Glossary

References

About the Author

Author

Kern Peng

Santa Clara, California, United States

Learn more about Kern Peng >>

Dr. Kern Peng holds two doctorate degrees, one in mechanical engineering specializing in nanocomposite materials, and the other in business administration specializing in operations management. He also holds an MBA in computer information systems and a BS in industrial engineering.

Dr. Peng designed and has been teaching the Equipment Management course at Santa Clara University, Santa Clara, California, since 2001. In addition, he regularly teaches four other master level courses in engineering management at SCU. Before that, he also taught MIS courses at San Jose State University, San Jose, California.

Dr. Peng has more than 26 years of people and project management experience in engineering and manufacturing, with over 19 years at Intel Corporation. He has mastered all aspects of engineering and manufacturing management and has proven results in finding innovative solutions to business and engineering problems. He has been accorded more than 50 career awards in the areas of engineering design; software development; technical paper publication; problem resolution; project management and execution; teamwork; and leadership.

Subject Categories

BISAC Subject Codes/Headings:
BUS053000
BUSINESS & ECONOMICS / Quality Control
BUS070050
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
BUS082000
BUSINESS & ECONOMICS / Industrial Management
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing