About this title

This textbook is designed to assist companies, regardless of the type of industry or facility, to develop equipment management strategies, which when implemented, will virtually eliminate equipment malfunctions or breakdowns. This is important since companies today are incurring higher and higher levels of equipment downtime and lost efficiencies. This impacts the company's financial standing since they will try to compensate for their equipment problems by:

1. Investing in redundant equipment, increasing the asset base value and thus negatively impacting their profitability.
2. The lack of asset performance will reduce the capacity of the equipment, reducing the company's ability to provide its product or service at the design capability of the equipment. This reduction in the output of the equipment will reduce the income generated (Return on Assets), thus negatively impacting their profitability.

The solution to the above problems is to focus on optimizing the utilization of the assets by implementation of strategies to eliminate all equipment breakdowns. In reality, whether a function loss or a function reduction breakdowns, all breakdowns impact a company financially. Zero breakdown strategies are designed to provide cost effective solutions to equipment problems that will allow companies to realize the maximum return on investment in their assets.

Acerca del Autor - Terry Wireman

Senior Vice President, Strategy
Vesta Partners

Terry is the senior vice president of strategic development. He leads Vesta’s maintenance and reliability seminars and training, and provides strategic guidance to help the firm shape its market strategy and long-term direction. For over four decades, Terry has been specializing in the improvement of maintenance management and reliability.

He helps customers develop “best-in-class” maintenance and reliability policies and practices. As an international expert in maintenance/asset management, he has assisted hundreds of clients in North America, Europe and the Pacific Rim to improve their maintenance and asset effectiveness.

In addition, he has authored twenty four textbooks and scores of white papers and articles related to maintenance management process and technology.

Terry is currently a member of the US Technical Advisory Group working on producing the ISO-55000 standard. Terry is committed to keeping Vesta on the forefront of thought leadership pertaining to maintenance and reliability strategies.

Contents

Chapter 1: Zero Breakdown Concepts

• Zero Breakdown Strategies
• Breakdowns
• Introduction to Zero Breakdown Enablers
• Defining Maintenance
• Maintenance Organization and Staffing

SECTION 1 — Equipment Component Fundamentals

• Chapter 2: Lubrication Fundamentals
  • Lubrication Objectives
  • Lubricant Application Methods
  • Types of Lubricants
  • Methods for Applying Lubricants
• Chapter 3: Fastening Fundamentals
  • Screw Threads
  • Fasteners
  • Bolt Grades
  • Nuts
• Chapter 4: Bearing Fundamentals
  • Plain or Sleeve Bearings
  • Rolling Element Bearings
  • Ball Bearings
  • Roller Bearings
  • Maintenance Practices
  • Shaft and Housing Fits
  • Mounting of Bearings
• Chapter 5: Belt Drive Fundamentals
  • Types of Belts
  • Flat Belts
  • Flat Belt Maintenance
  • Comparison of Flat Belts to V-Belts
  • V-Belts
  • V-Belt Installation
  • V-Belt Maintenance
  • Timing Belts
  • Ribbed Belts
• Chapter 6: Roller Chain Fundamentals
  • Roller Chain Links
  • Installation of Roller Chain
  • Roller Chain Wear
  • Types of Chain Failure
  • Common Chain Problems
• Chapter 7: Gear Drive Fundamentals
  • Spur Gears
  • Helical Gears
  • Herringbone Gears
  • Internal Gears
  • Rack and Pinion Gears
  • Worm Gears
  • Bevel Gears
  • Lubrication of Gears
  • Backlash
  • Gear Tooth Failures
• Chapter 8: Coupling Fundamentals
  • Types of Couplings
  • Installing a Coupling
  • Heating the Coupling
  • Key Size
  • Coupling Bolts
  • Lubrication
  • Alignment of Couplings
• Chapter 9: Sealing Fundamentals
  • Stuffing Box
  • Packing Materials
  • Installation of Packing
  • Mechanical Seals
  • Installation of a Mechanical Seal
  • O-Ring Packing
  • Lip Packing
• Chapter 10: Fluid Power Fundamentals
  • Viscosity
  • Density
  • Specific Gravity
  • Pressure
  • Pump Inlet
• Chapter 11: Hydraulic System Fundamentals
  • Reservoir
  • Filters
  • The Pump
  • Pump Flow and Pressure
  • Actuator
• Chapter 12: Pneumatic Fundamentals
  • Building a Pneumatic System
  • Compressor
  • Inlet Filter
  • Intercooler
  • Aftercooler
  • Dryers
  • Receiver
  • Filters
  • Regulator
  • Lubricator
  • Directional Control Valves
  • Flow Control Valve
  • Actuator

SECTION 2—Application of the Zero Breakdown Strategies

• Chapter 13: Maintaining Basic Conditions
  • Equipment Cleaning
  • Tightening Procedures
  • Proper Lubrication
• Chapter 14: Maintaining Operating Standards
  • Standardizing Operating Methods
  • Operating Conditions
  • Construction Standards
  • Elimination of Contamination
• Chapter 15: Deterioration Prevention
  • Equipment Restoration
  • Predictive and Reliability Tools
  • Standardization of Repair Policies and Procedures
  • Standardized Spare Parts
  • Storage of Spare Parts
  • Accessibility of Equipment
• Chapter 16: Improving Design Weaknesses
  • Best Practices
  • Vibration
• Chapter 17: Preventing Human Error
• Chapter 18: Beyond the Basics
  • Elimination of Minor Problems
  • Considerations for Improvement
  • Financial Measurements and the Overall Equipment Effectiveness
• Chapter 19: Financial Considerations of Zero Breakdown Strategies
  • Zero Breakdowns: Cost or Profit?
  • Standard Cost Justification
  • Additional Savings Considerations

APPENDIX A—Troubleshooting Fundamentals

• Bearings
• Belt Drives
• Chain Drives
• Gear Drives

APPENDIX B—Hydraulic Troubleshooting
APPENDIX C—Pneumatic Troubleshooting
APPENDIX D—Glossary
About the Author