Equipment Management in the Post-Maintenance Era: Advancing in the Era of Smart Machines
- Length: 260 pages
- Edition: 2
- Language: English
- Publisher: Productivity Press
- Publication Date: 2021-11-09
- ISBN-10: 0367516993
- ISBN-13: 9780367516994
- Sales Rank: #0 (See Top 100 Books)
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: Advancing in the Era of Smart Machines 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. Fundamentally, it:
- 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.
More specifically, 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.
This second edition addresses the role of the development of the Internet of Things (IoT) and significant advancements in artificial intelligence (AI) and machine learning (ML) in enabling a new generation of smart machines, which have in turn laid the foundation for Industry 4.0. Equipment utilizing IoT and sensors can monitor components and allow them to be serviced at an exact time without the need for a preventive maintenance schedule. Moreover, equipment replacement rarely occurs at the end of the piece of equipment’s natural life; rather, replacement is driven by the introduction of new technologies and products, all of which lead to less maintenance activities and reduces the importance of the traditional maintenance function. Maintenance departments today operate with fewer employees and smaller budgets. At a point when machines are smart enough to keep themselves running or equipment is rendered obsolete by better equipment in a short time, such as with computers and cellphones, companies do not need a maintenance department.
This updated edition reiterates the importance of transitioning to the post-maintenance era to effectively manage today’s sophisticated, smart yet expensive equipment. Many changes the author predicted a decade ago are accelerating in the IoT era. Equipment management is moving further away from the maintenance era and advancing deeper into the post-maintenance era. The trend for smart machines is very clear and companies that do not upgrade their equipment will lose their competitiveness. As equipment and factories become smarter, companies must change their practices and organizational structures to manage the new generation of equipment for Industry 4.0.
Cover Page Half Title Page Title Page Copyright Page Dedication Page Contents Preface Acknowledgments About the Author Chapter 1 Introduction to Equipment Management Background Maintenance Management Equipment Management Key Equipment Terminology Equipment States Equipment Time Equipment Actions Equipment Failure Patterns Equipment Performance Measurements Chapter 2 Development of Equipment Management: From Pre-Maintenance to Maintenance Era 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 Chapter 3 Advancing in the Post-Maintenance Era From Robotic Automation to Smart Machine to Smart Factory Introduction The New Business Environment Operational Changes Equipment Characteristics Management Concept Development The Issues of Maintenance Problems in Objectives Structural Inefficiency Unsuitable for Changing Environment The Post-Maintenance Era Phase 6: Robotic Automation Phase 7: Smart Machine Phase 8: Smart Factory Chapter 4 The Systems View of Equipment Management Introduction Environmental Suprasystem Goals and Values Subsystem Structural Subsystem Technical Subsystem Psychosocial Subsystem Managerial Subsystem Chapter 5 Strategic 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 Work Environment Improvements Management Changes Summary of the Changes Note Chapter 6 Adoption of the Maintenance Concepts 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 Summary of Preventive Maintenance Reliability-Centered Maintenance Predictive Maintenance Maintenance Prevention Total Productive Maintenance Terotechnology Chapter 7 Equipment Management Logistics Introduction Planning and Budgeting Strategic Planning Headcount Planning Budget Planning Tactical Planning Training and People Development Customer Services and Management Vendor, Supplier, and Contract Management Inventory Management Chapter 8 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 Quality Indicators Purpose Format and Variation Presentation Cost Performance Indicators Cost rates Purpose Format and Variation Presentation Cost Breakdown by Categories Purpose Format and Variation Presentation Integrated Indicators Comparative Indicators Purpose Format and Variation Presentation Composite Indicators Purpose Format and Variation Presentation Chapter 9 Computerized Management Systems Introduction CMMS Functions Equipment Module Work Order Module Preventive Maintenance Module Safety Module Labor Module Inventory Module Financial Module Calendar Module CMMS Features Accessibility and Security Notification and Communication Data Entry and Presentation Integration Flexibility and Customization From CMMS to CEMS Implementation Chapter 10 Transformation to the Post-Maintenance Era Introduction Environmental Studies Managerial Preparedness Goal and Value Changes Psychosocial Changes Technical Changes Structural Changes Glossary References Endnote Index
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