Contents

• 1. Introduction to Maintenance

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  Introduction, Maintenance Objectives, Maintenance Functions, Maintenance Organization, Requirement of Maintenance Organization, Types of Maintenance Organization, Role of Maintenance Organization, Administration of Maintenance System, Need of Maintenance Planning, Benefits of Maintenance Planning, Maintenance Policies, Types of Maintenances Systems, Planned Maintenance, Preventive Maintenance, Running Maintenance, Shutdown Maintenance, Corrective Maintenance, Breakdown Maintenance, Scheduled Maintenance, Reliability Centered Maintenance (RCM), Emergency Maintenance, Block Replacement Policy, Age Replacement Policy, Periodic Replacement Policy, Maintenance Planning, Analysis of Data Prior to Planning, Objectives of Maintenance Planning, Major Functions of Maintenance Planning, Scheduled Maintenance, Cost of Maintenance Versus Cost of Equipment, Cost of Equipment, Cost of Maintenance, Production Delays, Inspection, Objectives of Inspection, Types of Inspection, Inspection Intervals, Inspection Reports, Card History System, Review Questions.
   
  2. Predictive Maintenance

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  Introduction, Equipment Wear Records, Establishment of Standard, Equipment Used in Predictive Maintenance, Computerized Maintenance, Computerized Maintenance Management System (CMMS), Benefits of Using CMMS as a Management Tool, Selection of CMMS, Benchmarking, CMMS Implementation, Problems Encountered with CMMS, Total Productive Maintenance (TPM), Objectives of TPM, Major Components of TPM, Implementation of TPM, Measuring Overall Effectiveness of Equipment, Benefits of TPM, Condition Monitoring, Types of Condition Monitoring Systems, Benefits of Condition Monitoring, Methods of Condition Monitoring, Non Destructive Testing (NDT), Classification and Selection of NDT, Types of Flaws and Their Detection Techniques, Methods and Techniques of NDT, Application of NDT, Limitation of NDT, Liquid Penetrant Testing, Basic Principal, Experimental Procedure, Flow Diagram, Characteristics of the LP Testing Materials, Uses of LPT, Magnetic Particle Testing, Principle of MPT, Magnetic Particle Inspection, Magnetism, Magmatic Field Orientation and Flaw Detectability, Equipment Used for MPT, Ultrasonic Testing, Basic Principle of Ultrasonic Testing, Working of Ultrasonic Testing, Operating Techniques, Equipment Used in Ultrasonic Testing, Data Presentation, Vibration Analysis, Vibration Basics, Vibration Measurement, Working of Vibration Analysis, Assets in Vibration Analysis Technique, Equipment Problems Detected During Vibration Analysis, Areas of Application for Vibration Analysis, Oil Analysis, Sampling Procedures, Applying Oil Analysis, Oil Analysis Testing, Particle Analysis, Radiographic Testing, Basic Principle of Radiographic Testing, Nature of Penetrating Radiation, Properties of X-rays and Gamma Rays, Radiographic Film, Geometric Unsharpness, Filters in Radiography, Future Direction of Radiographic Education, Review Question.
   
  3. Reliability

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  Introduction, Definition of Reliability, Causes of Failure, Failure Data Analysis, Failure Rate, Mean Failure Rate, Failure Density, Hazard Function or Hazard Rate, Mathematical Analysis, Mean Time to Failure (MTTF), Mean Time Between Failure (MTBF), MTTF v/s MTBF, Failure Modes and Bathtub Curve, Failure or Hazard Rate Models, Constant Failure Rate Model, Weibull Distribution, Weibull Analysis, Mean and Variance of Weibull, MTTF, Skewness and Kurtosis, Weibull Plotting, Estimation of Parameters, Solved Questions, Review Question.
   
  4. System Reliability

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  Introduction, Series Configuration, Parallel Configuration, Mixed Configuration, Specific Hazard Models, Constant Hazard Rate Model, Linearly Increasing Hazard Rate Model, Calculation of MTTF, Series Systems, Parallel System, An r–out of–n Structure, Reliability Improvement, Pareto Analysis, System Simplification, Usage of Better Components, Derating, Redundancy, Controlling the Working Environment, Maintenance, Process Control and Quality Assurance, Removing Early Failures by Burn in, Worst Case Design, Human Reliability, Redundancy, Reliability based Design Optimization, Solved Examples, Review Question.
   
  5. Spare Parts Management

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  Introduction, Management of Spare Parts, Features of Spares, Categorization of Spares, Cost Considerations, Ordering Cost, Choice of Equipment, Inventory Cost, Stock-out Cost, Techniques of Cost Reduction, Selective Control of Spare Part, Inventory, Inventory Control of Spare, Factors Affecting Inventory, Safety Stock, Concept of Economic Order Quantity, Inventory Control Approaches, Periodic Review System (P-System), Differences between Q-System and P-System, Solved Examples, Review Questions.
   
  P. Paper