Absolute Losses
Production deferred or lost due to the specified element or system,
as a percentage of the total potential production.
Acoustic Emission Analysis
Like vibration analysis, patterns of acoustic emission
spectra are monitored and diagnosed. Acoustic emission analysis
technology is applied to study bearing faults, detect flaws and cracks in
welding and pipe-work, and to study de-lamination, de-bonding, and fracture in
aerospace materials.
Activity-Based Costing (ABC)
A system that tracks costs based on the activities that are
responsible for driving costs in the production of manufactured goods.
After Sales Service
All services proposed by the vendor or manufacturer after
the purchase.
Agile Manufacturing
Tools, techniques, and initiatives that enable a plant or
company to thrive under conditions of unpredictable change. Agile manufacturing
not only enables a plant to achieve rapid response to customer needs, but also
includes the ability to quickly reconfigure operations-and strategic
alliances-to respond rapidly to unforeseen shifts in the marketplace. In some
instances, it also incorporates "mass customization" concepts to
satisfy unique customer requirements. And, in the broadest sense, it includes
the ability to react quickly to technical or environmental surprises.
Alignment (Precision)
Refers to bringing or placing machine(s) shaft(s) in
line. Misaligned shafts often cause problems with machine components
(i.e. bearings). Specialized tools and personnel for precision
alignment exist. A number of tools are based on laser technologies.
Alliance (Contract)
An alliance is a long term commitment between two or more
entities for the purpose of achieving clearly stated business objectives by
maximizing the effectiveness of each participant’s skills and resources,
leading to an "alliance contract".
Analysis
(1) A step-by-step process of determining the solution to a
problem. (2) The collection, viewing, and examination of data and information.
(3) The process of determining the composition of a substance or material using
chemical or physical methods.
Annual Inventory Turns
A measure of asset management that is calculated by dividing
the value of annual plant shipments at plant cost (for the most recent full
year) by the average total inventory value at plant cost. Total inventory
includes raw materials, work in process, and finished goods. Plant cost
includes material, labor, and plant overhead.
Anomaly
Something irregular or inconsistent.
Assessment / Audit
A process that attempts to quantify the actual status of a
customer’s maintenance system to identify opportunities for improvement.
Asset
An entity with monetary value. In maintenance context, an
asset is commonly considered to be any component of a plant or its equipment.
For example, compressors, gearboxes, etc. A motor is also an asset as it is a component of a larger manufacturing unit.
Asset Efficiency Optimization (AEO®)
A key aspect of any world-class asset management program is
a proactive, efficient work management process, designed to ensure the
effective performance of maintenance on critical assets. To achieve maximum
return on investment and maintain the greatest degree of productivity, it is
pivotal that organizations have a process that effectively translates asset
information to knowledge, and ultimately releases value from that knowledge. To
help organizations achieve these goals, SKF offers Asset Efficiency Optimization
(AEO), a management process designed to achieve maximum efficiency and
effectiveness from work management activities focused on business goals for the
facility.
The AEO process encompasses four key elements: Strategy,
Identification, Control and Execution. Within each of these elements, the
coordination and participation of three essential facets within the
organization — process, culture, and technology — is paramount to the overall
impact of AEO.
Asset Knowledge Science (AKS)
An SKF process of documenting asset knowledge relevant to
monitoring and diagnosing asset anomalies. The process encompasses generic
literature, OEM and SKF information, and asset unique details. The goal is to
provide a structure to justify which measurements are needed to detect and
diagnose failures in an early stadium. The AKS is used to tune an SKF
decision-support system called @ptitudeTM.
Figure: Asset Knowledge Science hierarchy.
Asset Management
The organization of an asset’s life cycle to achieve the
lowest life cycle cost with the maximum availability, performance efficiency,
and highest quality (maximum OEE). In other words, asset management is the
systematic process of planning and control of a physical asset throughout its
life. This may include the specification, design, and construction of the
asset, its operation, maintenance and modification, and its disposal.
Asset management provides a strong focus on technical aspects of a facts-based,
proactive management attitude with a mission, vision, and objectives derived
from that of the company. (U.K. Institute of Asset Management)
Asset Integrity
Asset integrity is the fitness of an asset to be operated as
intended, and to perform as intended, with an acceptable risk of failure over
its service life.
Asset Register
In maintenance this term usually refers to a formal,
structured listing of the plant and machinery at a given location.
Asset Utilization
Percentage of time a plant or equipment is operating at
maximum demonstrated production rate, with perfect quality and defined yield.
Assignment Clause
A source of variation in a process that can be isolated,
especially when its significantly larger magnitude or different origin readily
distinguishes it from random cause of variation. Synonym - special cause.
Availability
Availability is the probability that a system or component
is performing its required function at a given point in time, or over a stated
period of time when operated and maintained in a prescribed manner. In
other words, the proportion of total time that an item of equipment is capable
of performing its specified functions. The general observation of availability
is:
By taking different measures for uptime and downtime,
different availability measures are obtained.
Availability (Inherent)
Inherent availability is defined as MTBF / (MTBF + MTTR).
Availability increases by increasing reliability (MTBF) and maintainability (1/
MTTR). For example: MTBF = 1000 hours, MTTR = 48 hours. Then the
availability is 1000 / 1048 = 95%. The inherent availability is solely based on
the failure distribution and repair-time distribution, assuming no supply and
maintenance delays, and no planned (preventive / corrective) maintenance. It is
considered as an equipment design parameter. Inherent availability
fulfills the need to distinguish expected performance between planned
shutdowns.
Availability (Achieved)
In the definition of achieved availability, the mean time
between maintenance (MTBM) is used as measure of uptime. This mean time between
maintenance includes both unplanned and planned maintenance. The mean
(expected) system downtime includes unplanned and planned
(preventive/predictive) maintenance, but does not include supply or
maintenance resources delays. Achieved (equipment) availability fulfills the
need to distinguish availability when planned maintenance shutdowns are
included, whereby it assumes zero supply and maintenance resources delay times.
Availability (Operational)
Similar to achieved availability, but in the operational
availability also the supply and maintenance resource delays are included in
the mean system downtime. Operational availability is required to isolate the
total effectiveness and efficiency of maintenance operations.
Remark: the mean time between maintenance and the
mean system downtime can be measured in both "clock" or
"calendar" time. Clock time is scheduled operating time, or
"manned hours". When measuring in calendar time, the term generalized
operational availability is sometimes used.
Remark: by definition, inherent availability is
higher or equal to achieved availability, and achieved availability is higher
or equal to operational availability.
Available Hours
The total number of hours that a piece of equipment is
capable of performing its specified functions. It is equal to the total
hours in any given period minus all the downtime hours.
Average Life
How long, on average, a component lasts before it suffers a
failure. Average life is commonly measured by Mean Time Between Failures
(MTBF), and is usually expressed in hours.
Regarding rolling element bearings and grease lubrication,
the average life is calculated according general formulas (please refer to the
SKF General Catalogue).
Autonomous Maintenance
Operators in independent groups carry out routine
maintenance and preventive maintenance. These groups, which may include
maintenance workers, solve problems without management intervention. The
maintenance department is only called on for bigger problems that require more
resources, technology, or downtime.
Backlog
Work that is not completed by the nominated "required
by date." The period each work order is overdue is defined as the
difference between the current date and the "required by date." All
work that doesn’t have a specified required by date is generally included on the
backlog. Backlog is often measured in crew-weeks, the total number of
labor hours represented by the work on the backlog, divided by the number of
labor hours available in an average week. As such, backlog is one of the
common key performance indicators in maintenance.
Balanced Scorecard
A "top–down" method of translating an
organization's mission and strategy into tangible linkages, interrelationships,
specific activities, and measures necessary for success. Reliability and
maintenance issues are integrated into an overall business scorecard or
identified in a stand-alone scorecard.
See http://www.balancedscorecard.org/.
Band-Aid
A known temporary fix to a problem that may have to be performed
one or more times until a permanent fix can be performed. ( A permanent fix may
consist of scheduled down time requirements, re-engineering, new procedural
developments, etc.)
Baseline Measurements
A set of measurements (or metrics) that seeks to establish
the current or starting level of performance of a process, function, product,
firm, etc. Baseline measurements are usually established before implementing
improvement activities and programs.
BASEEFA
British Approvals Service for Electrical Equipment in
Flammable Atmospheres. A certification body for electrical and electronic
equipment for use in hazardous areas. In 1987 it was brought together
with the Mining Equipment Certification Service to form the Electrical
Equipment Certification Service (EECS).
BDM
See Breakdown Maintenance.
Benchmarking (Competitive)
The process of consistently researching new ideas, methods,
practices, and processes, and adapting, adopting, and implementing their best
features. It is the continuous procedure of measuring one’s products,
services, and practices against competitive "best in class" companies
or organizations for the purpose of seeking improvement.
See Key Performance Indicators.
Benchmarking (External)
The process of consistently researching new ideas, methods,
practices, and processes, and adapting, adopting, and implementing their best
features. It is the continuous procedure of measuring one’s products,
services, and practices against external companies or organizations for the
purpose of seeking improvement.
See Key Performance
Indicators.
Benchmarking (Generic)
The process of consistently researching new ideas, methods, practices,
and processes, and adapting, adopting, and implementing their best
features. It is the continuous procedure of measuring one’s products,
services, and practices against companies or organizations that carry out the
same or similar functions (e.g. warehousing) for the purpose of seeking
improvement.
See Key Performance
Indicators.
Benchmarking (Internal)
The process of consistently researching new ideas, methods,
practices, and processes, and adapting, adopting, and implementing their best
features. It is the continuous procedure of measuring one’s products,
services, and practices within the company for the purpose of seeking
improvement.
See Key Performance
Indicators.
Break Down Maintenance (BDM)
"Unplanned" corrective maintenance performed on
equipment after the equipment has suffered a failure and has to be corrected
during a break down of the equipment. Break down maintenance indicates a lack
of planning.
See also RunTo Failure
BOI
Business Operation Income (after taxes).
Bottleneck
Any point at which production is slowed because demand
placed on a resource is equal to or more than capacity. Bottlenecks identify
machines that are critical to large sections of the production cycle.
Business Process Reengineering (BPR)
Business Process Reengineering or Business Process
Reorganization is itself a process that aims improving organizational
performance by improving its business processes. BPR came into use after
Michael Hammer and James Champy published their best-selling
"Re-engineering the Corporation" in 1993. Re-engineering means
'starting over' and the defining words are fundamental, radical, dramatic and process.
In short, starting with a clean piece of paper, to design an organization to
perform a process. Re-engineering is not about "continuous
improvement", which by definition is an examination and analysis of the
status quo where minute improvements are continuously applied to the existing
process. A combined approach of continuous improvement and radical change
(where needed) is aimed in Business Process Management (BPM).
Calendar-Based Maintenance
A maintenance strategy where specified activities (typically
preventative in nature) are undertaken on a predetermined schedule at fixed
intervals of time.
Call Back
A job where the maintenance person is called back because
the asset broke down again or the job was not properly finished the first time.
See Rework.
Capital Spares
Usually large, expensive, long lead time parts that are
capitalized (not expensed) on the books and depreciated. They are often
deemed as a "protection" against downtime.
CAV
Current Asset Value.
See Estimated
Replacement Value (ERV).
CBM
See Condition Based
Maintenance.
A manufacturing approach in which equipment and workstations
are arranged to facilitate small-lot, continuous-flow production-often in a
U-shaped cell. In a manufacturing "cell," all operations necessary to
produce a component or subassembly are performed in close proximity, thus
allowing for quick feedback between operators when quality problems and other
issues arise. Workers in a manufacturing cell are typically cross-trained and,
hence, able to perform multiple tasks as needed.
CEN
Comité European
de Normalisation.
European Committee for Standardization.
CENELEC
CENELEC is the European Committee for Electro-technical
Standardization. It was established in 1973 as a non-profit organization
under Belgian Law. The European Commission in Directive 83/189/EEC has
officially recognized CENELEC as the European Standards Organization.
Channel
Term used within SKF to indicate an integrated or linked
production line from turning operation to packing.
Characteristic Life
The life at which 63.2% of the population has failed.
In the rolling elements bearing industry, L1 and L10 life
are generally used corresponding to the number of hours at which 1% and 10% of
the population has failed, respectively.
See Patterns of Failure.
Charge Rate
This is the rate that you charge for a mechanic or
engineer's time. In addition to the direct wages, it includes provision
for benefits and overhead (such as supervision, clerical support, shop tools,
truck expenses, and supplies).
Client Needs Analysis (CNA)
The Client Needs Analysis is a quick, SKF facilitated
assessment with focus on the SKF AEO solution. The Client Needs Analysis can be
completed in just a few hours and asks 10 assessment questions for each of the
four main facets of the AEO Process: maintenance strategy, work identification,
work control, and work execution. These 40 questions are designed to
investigate, quantify, and visualize the situation at the your facility.
Results are displayed in a graphical “spider chart” format which provides a
visual footprint of a particular plant assessment in accordance with
international standards/models of business excellence.
Collinear
When the rotational centers of two shafts form a single,
straight line then the shafts are said to be collinear.
Compliance Test
Test used to show whether or not a characteristic or a property
of an asset complies with state requirements.
Component
A system or subsystem piece that has the ability to perform
a defined function, and is physically replaceable.
Computer-Aided Design (CAD)
Computer-based systems for product design that may incorporate
analytical and "what if" capabilities to optimize product designs.
Many CAD systems capture geometric and other product characteristics for
engineering-data-management systems, production and cost analysis, and
performance analysis. In many cases, CAD-generated data is used to generate
tooling instructions for computer-numerical-control (CNC) systems.
Computer-Integrated Manufacturing (CIM)
A variety of approaches in which computer systems
communicate or "inter-operate" over a network. Typically, CIM systems
link management functions with engineering, manufacturing, and support
operations. In the factory, CIM systems may control the sequencing of
production operations, control operation of automated equipment and conveyor
systems, transmit manufacturing instructions to equipment or operators, capture
data at various stages of the manufacturing or assembly process, facilitate
tracking and analysis of test results and operating parameters, or a
combination of the above.
Computerized Maintenance Management System (CMMS)
Hardware and software system used to track work orders,
equipment histories, and preventive / predictive maintenance schedules; usually
integrated with support systems such as inventory control, purchasing,
accounting, and manufacturing; computerized system, to track, monitor, measure
and control maintenance and warehouse activities. (McKenna T & Oliverson R,
"Glossary of Reliability and Maintenance Terms", Gulf Publishing
Company, ISBN 0-88415-360-6 (1997))
Computerized Process Simulation
Use of computer simulation to facilitate sequencing of
production operations, analysis of production flows, and layout of
manufacturing facilities.
Condition Based Depreciation (CBD)
A form of depreciation that directly assesses and
measures the run down in service potential of an asset. It is based on an
auditable and cost-justified asset renewal plan. The cost of replacing
lost service potential over the next 10-30 years (the exact period depends on
the agency and the nature of the assets involved) is expressed as an annuity
over the period. That annuity is the depreciation estimate. CBD is
re-estimated on a continuous basis, based on a rolling future period. It
is only used for assets which are essentially renewable rather than
replaceable, i.e. infrastructure assets.
Condition Based Maintenance (CBM)
An equipment maintenance strategy based on measuring the
condition of equipment to assess whether it will fail during some future
period, and then taking appropriate action to avoid the consequences of that
failure. The condition of equipment is monitored using a variety of
objective technologies, through the use of statistical process control
techniques, by monitoring equipment performance, or through the use of the
human senses. The terms Condition Based Maintenance, On-Condition
Maintenance, and Predictive Maintenance are often used interchangeably.
Condition Monitoring
The use of objective technologies to measure the condition
of equipment. Vibration analysis, oil analysis, and thermography are
examples of condition monitoring techniques.
Conditional Probability Of Failure
The probability that an item will fail during a particular
age interval, assuming that it survives to enter that age.
Conformity
Fulfillment by a product, process, or service of the specified
requirements.
Reduction to maintenance input (hours, materials, management
time) to provide a given level of maintenance service. Increases in the
number of assets, or use of assets with fixed or decreasing inputs.
Contract Management
Contract management is a niche within the procurement
profession. It ranges from administrative aspects to the excitement and
challenge of major contract negotiation. Both procurement and contract
management demand competence in such areas as contract law, administration,
accounting, psychology, management, and planning. (From National Contract
Management Association, Vienna, Virginia, USA).
Continuous Replenishment Programs
Arrangement with supplier companies in which the supplier
monitors the customer's inventory and automatically replaces used materials,
eliminating the need for purchase orders and related paperwork.
Control Engineering
Control engineering is the area of method and technique to
automatically control industrial processes. A commonly used industry
method is the PID (Proportional, Integrative and Differential) control
algorithm, implemented in PLCs (Programmable Logic Controllers).
Core Damage
When a normally re-buildable component is damaged so badly
that it cannot be repaired.
Corrective Maintenance
Any planned or unplanned maintenance activity required to
correct a failure that has occurred or is in the process of occurring. This
activity may consist of repair, restoration, or replacement of components.
Corrosion (Moisture)
Corrosion (rust) is a chemical reaction on metal
surfaces. When steel is in contact with moisture, such as water or acid,
oxidation takes place, and subsequently, the formation of corrosion pits and
flaking occur.
Cost of Goods Sold (COGS)
Total (annual) cost of material, labor, and utilities to
produce the product.
Cost of Un-Reliability (CoUR)
The cost of lost opportunity. CoUR programs study plants as
links in a chain for a reliability system, and the costs incurred when the
plant, or a series of plants, fail to produce the desired result. The cost can
be categorized in maintainability and reliability cost.
CQI
Continual Quality Improvement.
See Kaizen Method.
Cpk
A statistical calculation of process capability based on the
relationship between process variability and design specifications. A good Cpk
value indicates that the process is consistently under control, i.e., within
specification limits-and is also centered on the target value. A Cpk value of
1.33 is typically considered a minimum acceptable process capability; as the
Cpk value approaches 2.0, the process approaches Six Sigma capability (3.4
defective units per million). The ability to achieve high Cpk values is often
related to how tight the specifications are set.
Criticality
The priority rank of a failure mode, based on some
assessment criteria such as operational and HSE (Health, Safety, Environment)
consequences, and the likelihood of failure occurrence.
Criticality Analysis
Criticality analysis is a method for identifying product or
process criticality for the purpose of prioritizing activities like design and
maintenance. It is aprocess of decomposing product or process into hierarchical
components, followed by study of their failure modes and effects, and (where
appropriate) their causes. Criticality is the combined measure of the failure
mode probability and the severity of its effects.
Cross Functional Teams
Teams of employees representing different functional
disciplines and/or different process segments who tackle a specific problem or
perform a specific task, frequently on an ad hoc basis.
CSA
Canadian Standards Association. CSA International is a
not-profit, non-statutory, voluntary membership association engaged in
standards development and certification activities. CSA standards are
often incorporated into government regulation, particularly in the fields of
health, safety, building construction, and the environment.
Current Asset Value (CAV)
See Estimated
Replacement Value
Customer Lead-Time
The time elapsed from receipt of an order until the finished
product is either shipped or delivered to the customer.
Damage
Something that reduces the value, effectiveness, or
usefulness of the thing affected.
Debris Monitoring
See Oil Debris Monitoring.
Deformation (by overload)
Overloading by static or shock loads, which leads to plastic
deformations (i.e. the formation of shallow depressions in steel surfaces).
Design for Reliability
A four-phase design process to build reliability into a
part, component, or system. The phases are concept, design and development,
full-scale development, and operational.
De-rating
Using an item in a way that applies stresses that are below
the recommended stress values.
DIN
DIN (Deutsches Institut für Normung) is a non-governmental
organization established to promote the development of standardization in
Germany and related markets. Their goals are to facilitate the
international exchange of goods and services, and to develop cooperation in the
spheres of intellectual, scientific, technological and economic
activity. Through the European standards organizations CEN and CENELEC,
DIN presents the German view of European standards, which is critical to
complete the single European market. Over 12,000 DIN standards cover a
wide range of topics including: physical quantities and units, fasteners, water
analysis, building and civil engineering (including building materials,
construction contract procedures (VOB), soil testing, corrosion protection of
steel structures), materials testing (testing machines, plastics, rubber,
petroleum products, semiconductors), steel pipes, machine tools, twist drills,
roller and ball bearings, and process engineering. DIN Handbooks
(covering subjects such as mechanical engineering, fasteners, steel, steel
pipes, and welding), and most DIN standards are available as English versions,
or English translations. (From http://www.cssinfo.com/info/din.html)
See Do It Now Work.
Discrete manufacturing
Manufacturing a product by means other than a continuous process. Examples of discrete manufacturing are:
- Mass production – for high volume production of an item at minimum unit cost. Increasingly this involves the use of specialized machines for some or all parts of the manufacturing process.
- Batch production typically employs general-purpose machines (as opposed to the special purpose machines employed for mass production).
- Individual production for items required in low volume (typically one-offs), which results in greatly increased unit costs.
Distributed Control System (DCS)
A system customized per facility/organization and designed
to meet the total measurement, control and real-time information requirements
of today's process plants. A single application to connect to subsystems such
as maintenance (CMMS), statistical process control (SPC), and advanced control.
Do It Now (DIN) Work
"Do It Now" means non-emergency work that has to
be done immediately. An example is moving furniture in the executive
wing.
Downsizing
A reduction in the number of employees that occurs due to
management decision, not associated with natural attrition.
Downtime
The time that an item of equipment is out of service, for
example as a result of equipment failure. The time that an item of equipment is
available but not utilized is generally not included in the calculation of
downtime. In other words, downtime is the time that the asset is not in a
condition to perform its required function. The downtime of an item includes
active maintenance time and delays due to awaiting spares, labor, facilities,
movement, etc. Unless otherwise stated, downtime due to failure is considered
to commence at the instant the item is deemed to have failed and to persist
until the equipment is again available.
EECS
The Electrical Equipment Certification Service (EECS) is
based at the UK Health and Safety Laboratory's Buxton research center. It
provides a range of testing and certification services primarily related to
equipment and systems intended for use in potentially explosive atmospheres.
The work of EECS originated with the Safety in Mines
Research Establishment in 1926, when testing of mining equipment to prevent
explosions was started in Buxton. That work continues with the Mining
Equipment Certification Service (MECS), a division of EECS.
With the growth of the petrochemical industry in the 1950s
and 1960s, the need for standards and a certification services outside of the
mining industry led to the development of the British Approvals Service for
Electrical Equipment in Flammable Atmospheres (BASEEFA). In 1987, MECS and
BASEEFA were brought together to form EECS.
Effectiveness
A measure of the degree to which an item, system, or person
can be expected to achieve a set of specific mission requirements. Performing
the correct task efficiently.
Efficiency
In a general sense, efficiency relates to competence: the
ability to do something well or achieve a desired result without wasted energy
or effort.
In engineering terms, efficiency is a measure of a machine's
energy effectiveness: the ratio of the amount of energy used by a machine to
the amount of work done. For example, the measurement of the amount of
heat produced per unit of fuel burned is a measure of a heating unit's
efficiency.
Electrical Current Analysis
An investigation of the electric current (spectrum) of
electric motors or generators. Through this analysis, irregularities (e.g.
broken rotor bars, cracked end-rings, high resistance joints) are
detected. Specialized tools and personnel exist for doing these
investigations.
Electronic Data Interchange (EDI)
(EDI) links-Information-system linkages, based on communication
protocols and document formats, which permit inter-company computer-to-computer
communications. EDI links not only speed communication, but also eliminate
re-keying of information and reduces the opportunity to introduce errors. A
typical EDI application might speed information exchange between a customer and
supplier company for purchase orders, invoices, or other transactions. EDI
communications are often facilitated through "electronic mailbox"
systems on third-party value-added networks.
Emergency Work
Maintenance work that requires immediate response from the
maintenance staff. Its urgency is usually associated with safety,
operational, health, or environmental effects. Emergency work is often
performed without a requisite work order issued in advance.
Enterprise Asset Management (EAM) Systems
Software application to support enterprise wide asset
management philosophy. A computerized maintenance management system with
extended functionality which typically includes timekeeping, project management,
human resources issues, payroll, core financial data, etc.
"Maintenance Management systems are often referred to
as Computerized Maintenance Management Systems (CMMS) or Enterprise Asset
Management (EAM) systems. The difference is essentially one of scale, and there
is no clear dividing line" (Campbell J D and Jardine A K S,
"Maintenance Excellence, Optimizing Equipment Life-Cycle Decisions",
Marcel Dekker Inc, ISBN 0-8247-0497-5 (2001)).
Enterprise Resource Planning (ERP) system
An Enterprise Resource Planning system refers to a system
comprised of a single or integrated suite of applications to manage enterprise
business functions, including finance, human resources, and order fulfillment.
Equipment Lifetime
Span of time over which equipment is expected to fulfill its
intended purpose.
Erosion (electric)
Electric erosion is damage to contact steel surfaces caused
by the passage of electric current. Small current leakage typically
results in small craters, and possibly flutes or discoloration. Large
craters can result from excessive voltage leaks.
ERP
See Enterprise
Resource Planning System.
Estimated Plant Replacement Value (EPRV)
The ERV of a plant. A plant can represent part of, or a
complete, production facility.
See Estimated
Replacement Value (ERV)
Estimated Replacement Value (ERV)
The cost of capital works required to replace specific
existing assets, including necessary facilities (such as buildings, energy, and
other supply systems) with new assets capable of producing the same quantity
and quality of output. This is a key value often used in benchmarking
activities at the highest level. It is not the book value, nor the current cost
accounting value, nor costs to build a state of the art replacement. ERV is an
estimate of the current replacement cost (normally the insurance value).
To calculate the ERV, determine if the original equipment
investment figures reasonably agree with equipment actually in use. Then
identify clusters of equipment by the year in which they were acquired.
Consider each cluster of investment and escalate it to a current value using a
selected inflation index (e.g., the Bureau of Labor Statistics Construction
Cost Index (BLS CCI)). Then the indexed clusters of investment are totaled to
get the current value of plant and/or equipment. The indexed value of the plant
could be compared with other plants recently built, adjusting for size and
available insurance values. Even when a company is self-insured, there is
normally an established "insurance value" to help define the
financial exposure the company risks. An insurance underwriter typically
prepares these values, even if the plant is self-insured. Underwriters follow a
procedure very similar to the one described.
ERV is often used to normalize maintenance cost as a
convenient basis for comparing plants of a similar type that vary in size. The
rationale for using the ERV rather than the original cost of the plant is to account
for construction cost escalation over time (inflation). Two relatively new
plants built 10 years apart could have original costs that vary by 50 to 100
percent. Maintenance cost/ERV can be used to set long-term goals, and targets
for plant reliability. World-class plants tend to fall in the range of 1 to 2.5
percent.
Event Tree Analysis (ETA)
Starting with an initiating event, event trees employ
forward logic to construct a graphical representation of subsequent
consequences. If successful operation of a system depends on an approximately
chronological, but discrete, operation of its units or subsystems, then an
event tree can be an appropriate analysis technique.
Expert System
An expert system is a software system designed for decision
support. It makes or evaluates decisions based on rules, empirical test
results, cases, or other knowledge sources. Expert systems are typically
used for assessment and diagnosis tasks that are perceived as
knowledge-intensive. The term “expert systems” originates from the 80's
and was used for rule-based systems only; a better term that covers the broad
range of "expert" system types is Knowledge-Based
Systems (KBS).
Failure
A lack of success in something, or an unsuccessful attempt
at doing something. A breakdown or decline in the performance of
something, or an occasion when something stops working or stops working
adequately. Note that "failure" is an event, as distinguished from
"fault" which is a "state."
See Functional Failure.
Failure Cause
The apparent cause of a functional failure, not to be
confused with the root cause, which is only determined through a Root Cause
Failure Analysis (RCFA). (Used interchangeably with Failure Reason).
Failure Characteristics
Terms used to describe the characteristics of a failure include hidden, predictable, preventable and random.
- A hidden failure singularly results in a complete loss of function without being immediately evident.
- A predictable failure displays some evidence, at an early stage, of the potential for failure, and a reasonable estimate of the time interval before full functional failure occurs.
- The term "preventable" describes those failures for which there is a reliable time interval or usage (such as number of cycles) before functional failure occurs.
- Random refers to a failure that occurs at any time and is not necessarily constrained by time or usage.
Failure Code
An alphanumeric code typically entered against a work order
in a computerized maintenance management system (CMMS), which indicates the
failure cause (e.g. lack of lubrication, metal fatigue, etc.). These
codes are employed to facilitate analysis of plant history.
Failure Consequences
A term originating from reliability-centered maintenance
(RCM). The consequences of all failures are classified as being either
hidden, safety, environmental, operational, or non-operational.
Failure Descriptor
The term failure descriptor refers to the apparent
observation of a failure. The failure descriptor must answer the question
of what caused the equipment to fail to perform or fulfill the required
function(s).
Failure Effect
A description of the events that transpire after a failure
has occurred as a result of a specific failure mode.
See failure consequences.
Failure Finding Interval
How often a failure finding task is performed. It is
determined by the frequency of failure of the protective device, and the
desired availability required of that protective device.
Failure Finding Task
A routine maintenance task, normally an inspection or a
testing task, designed to determine, for hidden failures, whether an item or
component has failed. A failure finding task should not be confused with
an on-condition task, which is intended to determine whether an item is about
to fail. Failures finding tasks are used in reliability-centered
maintenance (RCM), and are sometimes referred to as functional tests.
Failure Mode
The term failure mode refers to the observed way or
mechanism of failure. For a failure mode to be valid it must answer the
question: “What is the primary manner in which the associated failure
descriptor becomes evident?” Depending on the application, the definition
of failure mode may slightly vary.
In a detailed analysis, a failure mode can refer to a
physical event / mechanism that gave rise to a failure (e.g., moisture
corrosion, fatigue, wear). Or from a functional point of view, a valve
can have several failure modes such as, "fails to operate on demand, valve
leakage," etc. In a formal Reliability-centered Maintenance (RCM)
program, deeper failure modes are considered as failure causes.
Failure modes may also be defined according to the effect by
which a failure is observed. A high level model system may include the
following general failure modes:
- CRT: General critical failure resulting in 100% production loss.
- DEG: Degraded equipment performance, resulting in partial production loss while waiting for repair and 100% production loss during repair.
- INC: Incipient failure. Equipment failure did not result in immediate production loss. The failure was found during other repair / scheduled maintenance activities. 100% production loss during repair.
- UNK: No impact details are recorded in database. 100% loss of equipment item on repair.
Failure Mode, Effects (& Criticality) Analysis (FME(C)A)
FME(C)A is a procedure that analyzes failures (failure
modes) and determines their impact (effect) at both the local and system
levels. The analysis can be carried out from the lowest to the highest
level of the system (bottom up), which is commonly referred to as a hardware
analysis. Alternatively, the analysis can be carried out from the highest
level to the lowest level (top down) of the system, which is commonly referred
to as a functional FMEA. The functional FMEA considers the functional
failure of components within a system.
FMEA is applied in maintenance tasks, such as
reliability-centered maintenance (RCM) and risk-based maintenance (RBM).
The effects are generally classified as operational (production),
environmental, and safety effects. This procedure is used to plan tasks
to find minimum ratio between maintenance cost and cost due to failure effects.
FME(C)A is a structured method to determine equipment functions, functional
failures, and assess failure causes and effects.
Failure Patterns
See Patterns of Failure.
Failure Rate
Failure rate refers to the overall speed of failures, or the
number of failures that occur in a given time frame, usually expressed in
years. The total number of failures within an item population is
divided by the total time expended by that population during a particular
measurement interval under stated conditions. Failure rate is the ratio
of the number of failures that occur in an interval to the size of the original
population, divided by the length of the time interval. Other formats
include the number of failures per year, and in some cases, it is common to
express failure rate as the number of failures per hour, or the number of
failures of an item per unit time. This can be applied to:
- Observed failure rate: as computed from a sample
- Assessed failure rate: as inferred from sample information
- Extrapolated failure rate: projected to other stress levels
Failure Reason
Sometimes used to refer to the apparent root cause of a
functional failure, but not to be confused with the real root cause obtained
from a thorough root cause failure analysis (RCFA). Used interchangeably
with Failure Cause.
False Brinneling
False brinneling occurs in rolling element bearing contact
areas due to micro movements under cyclic vibrations, at times when the machine
is not rotating. Depending on the intensity of the vibrations,
lubrication / preservative condition, and load, a combination of corrosion and
wear occurs, which forms shallow depressions in the raceways. In the case
of a stationary bearing, the depressions appear at rolling element pitch and
may be discolored (red) and shiny.
FAS
Shipping term meaning “Free Along Side.” This means that the
price quoted for goods includes carriage to the ship, but does not include
loading or subsequent carriage costs.
Fatigue (Subsurface initiated)
Under the influence of repetitive (especially high) loads in
any metallic contact, structural changes occur in steel, and cracks are
initiated at a certain depth under the surface, due to volume changes of the
altered material. Cracks propagate through the material until they reach
the surface. In extreme cases, cracks further propagate until the
component completely fractures (ISO/CD 15243).
Fatigue (Surface initiated)
Surface initiated fatigue or surface distress refers to the
failure of any metal surface contact due to a fatigue process started
from the surface. Generally, a surface defect, such as a foreign particle
indentation or a corrosion pit, is the initiator. The fatigue process is
especially accelerated by a reduced lubrication regime (ISO/CD 15243).
Fault
A defect or imperfection. A fault develops when
physical degradation has occurred, but the degradation is not severe enough to
be termed as failure. A fault is absolute. This means there is a
sufficiently high degree of confidence that a detailed physical examination of
the component in question will show a fault that is absolutely supported by the
symptom(s).
Fault Tree Analysis (FTA)
Fault tree analysis is a deductive process by means of which
an undesirable event, called the top-event, is postulated, and the possible
ways for this event to occur are systematically deduced
Feedback
When used in a maintenance context, feedback means that
information from the individual failure history is accounted for in the task
list. The list increases when failure history is high, and decreases when
failure history is low.
In control engineer context, feedback means that
measurements are taken from a process and used to take (automated) control
actions (i.e., to keep a temperature constant over an operating range).
Finished-Goods Turn Rate
A measure of asset management that typically is calculated
by dividing the value of total annual shipments at plant cost (for the most
recent full year) by the average finished-goods inventory value. Plant cost
includes material, labor, and plant overhead.
Finished-Product First-Pass Yield
The percent of finished-products that meet all
quality-related specifications at a final test point. In process industries,
yield is often calculated as the percentage of output that meets target-grade
specifications (excluding saleable "off-grade" product).
Five-S (5-S) Concept
The “5-S Concept” was developed by the Japanese over a
period of time to ensure a culture of organization within the manufacturing and
service environments, which leads to higher quality. The 5 S’s, closely
translate from Japanese to English as Sort, Simplify, Shine, Standardize, and
Sustain.
Flow Chart
A flow chart is a diagram that uses graphic symbols to
depict the nature and flow of the steps in a process. Another name for this
tool is "flow diagram." A flow chart is a graphical representation of
a process, depicting inputs, outputs and units of activity. It can represent
the entire process at a high or detailed (depending on your use) level of
observation, allowing analysis and optimization of workflow.
FMEA
Failure Mode
Effect Analysis.
See Failure Mode,
Effects (& Criticality) Analysis (FME(C)A).
FMECA
See Failure Mode,
Effects (& Criticality) Analysis (FME(C)A).
FOB
See Free On Board.
Focused-Factory Production
A plant configuration and organization structure in which
equipment and manpower is grouped to create essentially self-contained
"mini-businesses," each with a specific product-line or customer
focus. A single plant may be divided into several focused-factory units,
designed around process flows, each of which has control over such support activities
as maintenance, manufacturing engineering, purchasing, scheduling, and customer
service.
Forecast/Demand Management Software
Software that provides front-end input to master production
scheduling systems and helps to optimize inventory planning. Such software not
only takes into account historical demand trends, but also may calculate the
impact of planned sales promotions, price reductions, and other factors that
cause spikes in demand levels.
Fracture (forced)
Forced fracture is caused by high stress concentration in
excess of material tensile strength by local overloading (e.g. by impact).
Fracture (fatigue)
Fatigue fracture results from frequently exceeding a fatigue
strength limit, often under bending condition or excessive compressive loads.
Cracks are initiated at little defects and propagate stepwise through the
component.
Free Along Side (FAS)
Shipping term meaning that the price quoted for goods
includes carriage to the ship, but does not include loading or subsequent
carriage costs.
Free On Board (City, Shipping point, or Delivered)
Free On Board (seller will load truck or rail car).
"FOB delivered" keeps the vendor responsible for the shipment until
it reaches your door. "FOB shipping point" or "FOB
originating city" makes you responsible for the shipment. If there
is a problem with a FOB originating city shipment, you still have to pay the
vendor and file a claim with the carrier.
Frequency of Inspection
The regularity with which inspections are undertaken. Typically these are:
- Annually (once per year)
- Bi Annually (twice per year)
- Quarterly (four times per year)
- Monthly
- Weekly
- Daily
- Once per shift
Fretting
Fretting corrosion (generally referred to as fretting)
consists of a chemical reaction activated by relative (sliding) micro movements
between steel surfaces. In case of bearings, this movement leads to
oxidation of the bore or outer diameter surfaces and becomes visible as powdery
rust and/or loss of material. The surfaces become shiny or discolored
(blackish - red). The failure develops as a result of poorly fitting (too
loose) components operating in combination with high loads and/or
accelerations.
Function
A definition of the objective that an equipment item intents
to achieve, with respect to its role in the process. The statement should
specify the operating context and contain a verb, a noun (object), and a
performance standard. For example: “To supply crude oil to the separator
V1022 at a flow rate of 60 m3 per hour and a pressure of between 5.5
Bar and 6 Bar.”
Function Check-out
Action taken after maintenance activities to verify that the
asset is able to perform the required function.
Functional Failure
A specific failure that refers to the termination of, or
degradation in the ability of an item to perform any one of the stated required
functions.
See Function.
Future Benefit PM
Preventive maintenance (PM) tasks that are initiated by a
breakdown rather than a schedule. The PM is done on a whole machine,
assembly line, or process after a section or subsection breaks down. This
is a popular method with manufacturing cells where the individual machines are
closely coupled. When one machine breaks, the whole cell undergoes a
preventive maintenance activity. Future benefit PM is considered "packaging
of opportunistic work" given that an opportunity has arisen to do that
work (often due to the failure of an associated piece of equipment).
Gantt Chart
A bar chart of scheduled activities that shows the duration
and sequence of activities and resources planned.
Go-Line
Used in relation to mobile equipment. Equipment
available but not being utilized is typically parked on the go-line. This
term is used interchangeably with Ready Line.
Hazard Rate
Hazard rate is the instantaneous speed of failure.
Hazard rate is the ratio of failures that occur in an interval to the size of
the population at the start of the interval, divided by the length of time.
HACCP
Hazard Analysis and Critical Control Points (HACCP) was started
by NASA in conjunction with the Apollo space program to insure astronaut food
supplies were safe to consume over the course of their mission. The logic was
simple for NASA; keep the astronauts from getting sick during the mission.
According to the United States Food and Drug Administration (FDA) HACCP is “a
state of the art approach to food safety.” Consisting of seven principles,
HACCP outlines the guidance for, and implementation of the food safety program
to include both animal and plant products.
HAZOP (Hazard and Operability)
HAZOP stands for a structured technique that may be applied
typically to a chemical production process, identifying hazards resulting from
potential malfunctions in the process. It is essentially a qualitative process.
A HAZOP would typically be undertaken by a multi-disciplinary team, asking a
series of "what if?" questions using guidewords representing
deviations from the intended process parameters. By undertaking a HAZOP at an
early design stage, potential problems can be avoided instead of having to make
costly modifications. HAZOP is similar in some respects to Reliability-centered
Maintenance (RCM), but not as rigorous in identifying underlying causes of
failure, and does not consider the possibility of avoiding such incidents
through applying appropriate proactive maintenance tasks.
Hidden Cost
All costs associated with either production or
maintenance. When associated with maintenance, hidden costs represent the
loss associated with unplanned downtime. Typically, hidden costs
represent between 1- 3% of a company’s revenues or, potentially between 30-40%
of profits.
Hidden Failure
A failure that does not become evident to the operating crew
under normal circumstances. This typically applies to protective devices
that are not fail safe (examples include standby plant and equipment, emergency
systems, etc.).
HSE
Health, Safety & Environment - generally referring to
relevant standards. Specifically in the UK, the abbreviation HSE also
stands for “Health and Safety Executive” – a UK Government Department that has
an impact upon maintenance (along with all other areas of a business).
HVAC
Heating, Ventilation, and Air Conditioning.
Iatrogenic
Failures that are caused by your own service person(s).
Improvement
Combination of all technical, administrative, and managerial
actions intended to decrease the dependency of an asset without changing its
required function.
An indentation (dent) is a plastic depression caused by
debris being pressed into a contact surface. Indentations can go hand in
hand with (abrasive) wear. Depending on the hardness of the particle,
sharp (often with raised edges) or smooth indentations result.
Infant Mortality
The relatively high conditional probability of failure
during the period immediately after an item returns to service.
Inherent Reliability
A measure of the reliability of an item, in its present
operating context, assuming adherence to ideal equipment maintenance
strategies.
See Reliability.
Inspection
Any task undertaken to determine the condition of equipment,
and/or to determine the tools, labor, materials, and equipment required to
repair the item.
Inspectors
In a maintenance sense the term refers to the nominated
person(s) that has primary responsibility for maintenance tasks.
Inspectors can be members of the maintenance department or any other department
(machine operators, drivers, security officers, custodians, etc).
Integrated Maintenance SolutionsTM (IMS)
A long-term SKF contract (2 years +) that is generally
performance-based. It includes key process actions known internally as the
"8 Steps to Maintenance Heaven." An IMS
contract brings together all areas of expertise offered by SKF, establishing a
continuous process of maintenance monitoring, analysis and improvement. It
provides a planned skills transfer program for maintenance and operations
personnel, and technology upgrades where required. The services and support
best suited to optimize asset efficiency and integrity (safety and environment)
are all included under one fixed fee performance based agreement.
Intervention (scheduled / planned)
Action taken systematically in a period of time independent
of machine condition. The time period may be fixed (calendar based) or
measured according to machine utilization (running hours based).
Intrinsic Safety
Intrinsic safety is intended for products in which the level
of electrical energy circulating or stored in the product is insufficient to
ignite a surrounding explosive atmosphere even under fault conditions.
Inventory
In accounting terms, inventory is a record of current
assets, which includes property and equipment owned (counting merchandise in
stock, value of work in progress, and work completed but not sold). In
maintenance terms it is frequently used to describe the list of equipment and
spare parts currently held in stock.
Inventory Management
The process by which inventory is controlled. Typically
this includes:
- Tracking usage of stock items
- Optimization of stock levels
- Control of costs
IS
See Intrinsic Safety.
ISO
International Standards Organization in Geneva, Switzerland
(http://www.iso.org/).
The full and correct title is the International Organization
for Standardization.
ISO 9000
An international quality-process auditing program, based on
a series of standards published by the International Standards Organization
through which manufacturing plants receive certification attesting that their
stated quality processes are adhered to in practice.
ISO 14001
International environmental management system (EMS) standard
developed by the International Standards Organization. The standard is designed
to address all facets of an organization's operations, products and services.
It covers environmental policy, resources, training, operations, emergency
response, audits, measurement, and management views. It contains five major
elements that an organization must satisfy to be registered or certified. These
elements are policy, planning, implementation and operations, checking and
corrective action, and management review.
Job Card
See Work Order.
Just In Time (JIT)
Used to describe a manufacturing process in which materials
arrive as close as possible to the time required. Implementation of "just
in time" techniques to reduce lot sizes, reduce setup times, slash
work-in-process inventory, reduce waste, minimize non-value-added activities,
improve throughput, and reduce manufacturing cycle time. JIT production
typically involves use of "pull" signals to initiate production
activity, in contrast to work-order ("push") systems in which
production scheduling typically is based on forecasted demand rather than
actual orders. In many "pull" systems, a customer order/shipment date
triggers final assembly, which in turn forces replenishment of component
inventory at upstream stages of production.
Kaizen Method
A term originating from Japanese industry relating to a
philosophy for continual quality improvement (CQI). Individuals and teams
feel empowered to take personal steps toward minimization of:
- Defective finished products and inventory (zero defects)
- Inefficient work methods, and unnecessary movements and transfers while handling goods
- Process and operational weaknesses
KBS
See Knowledge Based Systems.
Key Performance Indicators (KPI)
A select number of key measures that enable performance to be
monitored against targets. The KPI will indicate how well the business is doing
at attaining its goals. In a manufacturing quality scenario, this may be the
amount of scrap or rework that gets metered. In a service quality scenario,
such as an insurance company, this may be the open inventory of unprocessed
claims. In brand management, market share in itself and in comparison with
competing brands is sure to be relevant. In logistics, on-time deliveries,
empty return loads, or missing items are candidate indicators.
KM
See Knowledge Management.
Knowledge-Based Systems (KBS)
A wide range of software systems that support decision
making for knowledge intensive tasks (i.e. failure diagnosis). The system
is based on knowledge that resides in heuristic rules, cases, empirical test
results, or partly physical models.
See Expert Systems.
Knowledge Management (KM)
The whole of initiatives and instruments that support
creation and flow of knowledge through an organization. This includes
initiatives from human resources, information technology, and quality
processes. Examples are job rotation, partnering, yellow pages, best
practice databases, etc.
KPI
See Key Performance
Indicators.
Labor Turnover Rate
A measure of a plant's ability to retain workers, expressed
as a percentage of the production workforce that departs annually-or an
annualized rate of employee departures. High turnover rates often indicate
employee dissatisfaction with either working conditions or compensation.
Labor Per Product (LPP/LPU)
Also known as Labor Per Unit, is calculated using vague
estimates of material, Direct Labor, and overhead cost. The cost per unit is
normally used for external reporting only, not management decision. Example:
Direct labor (operator) X 30% fringe benefits = LPP = LPU.
Latent Fault
An existing fault that has not yet been detected.
LCC
See Life Cycle Costing.
Lean Manufacturing
The systematic identification and elimination of waste to
reduce manufacturing or operating costs.
Life Cycle Cost
The total cost of a piece of equipment or system over its
entire lifetime; the total of all costs generated or forecasted to be generated
during the design, development, production, operation, maintenance, and support
processes. Life cycle costs include direct, indirect, recurring, non recurring
costs such as acquisition, installation, operating, maintenance, upgrades, and removal
or disposal costs.
Life Cycle Costing (LCC)
A process of estimating and assessing the total costs of
ownership, operation, maintenance, and disposal costs of a piece of equipment
during its projected equipment life. LCC is typically used to compare alternative
equipment design or purchase options to select the most appropriate
option. LCC is the practice of obtaining over their lifetime the best use
of the physical assets at the lowest cost to the entity. This is achieved
through a combination of management, financial, engineering and other
disciplines.
Life Cycle Costing is sometimes referred to as
"Terotechnology" but terotechnology is really the ‘science’ of life
cycle costing; it is concerned more with the analysis of component data and
derivation of the appropriate component life cycles than with
application. Terotechnology is a more common term in manufacturing
industry where it is applied to analyzing the life spans of relatively short
lived plant and equipment rather than longer lived infrastructure assets.
Loading Time
The available time is derived by subtracting the planned
downtime from the available time per day or week, etc.
Loss Of Revenues
Total revenues lost minus direct avoided cost of production
(generally materials or energy).
Log Sheet
A document on which brief details of minor activities and
repairs are recorded.
Lubricant
A friction reducing substance. A substance, typically
oil or grease, applied to a surface to reduce friction between moving parts.
Lubricant Analysis
See oil analysis.
Lubrication Management
Lubrication management at a production facility includes all
activities related to the lubrication of machinery. Included, but not limited
to, are the following activities:
- Establishing a lubrication strategy "where to go, in what period".
- Planning for lubrication improvement "projects".
- Resource planning: people, tools, software, etc.
- Establishing lubrication plan: lubrication selection, schedules, routes, intervals, quantities, etc.
- Establishing recording database and reporting system.
- Establishing health, environmental, and safety procedures.
- Optimizing supply and storage.
- Implementation – ensuring the plan and operating procedures are followed.
Maintainability
Maintainability is the probability that a failed component
of system will be restored or repaired to a specified condition within a period
of time when maintenance is performed according with prescribed procedures. The
prescribed maintenance procedures include not only the manner in which repair
is to be performed but also the availability of maintenance resources (people,
spare parts, tools, and manuals), the preventive maintenance program, skill
levels of personnel, and the number of people assigned to the maintenance crew.
Restoration times are commonly characterized by the log normal distribution.
Maintainability Improvement
A maintenance engineering activity that looks at the root
cause of breakdowns and maintenance problems and designs a repair that prevents
future breakdowns. Maintainability improvement places an emphasis on
making equipment easier to maintain.
Maintenance
Combination of all technical, administrative, and managerial
actions during the life cycle of an asset intended to retain it in, or restore
it to, a state in which it can perform the required function (UTEK, 13306:1998
E). So, maintenance covers any activity carried out on an asset to repair
equipment, or to ensure the asset continues to perform its intended functions.
Maintenance includes all actions taken to prevent or reduce the consequences of
failure.
Maintenance Activity
Maintenance activities are the specific actions defined in a
Computerized Maintenance Management System (CMMS), taken to prevent or reduce
the consequences of failure. For example, component replacement,
lubricant analysis, or vibration monitoring are maintenance activities.
Maintenance Categories
Maintenance categories describe the primary function of the
maintenance activity. Maintenance categories include the following:
inspection, condition monitoring, non-destructive testing, overhauls, and fault
finding.
Maintenance Contractor Expenses
Cost of labor and material for contracted maintenance
services. This does not include contract labor for capital projects.
(Total) Maintenance Cost
All direct and indirect costs regarding maintenance
activities. Direct costs are costs charged to a maintenance budget as
fixed costs (e.g. personnel, materials, subcontractors, and overhead).
Indirect costs are related to loss of revenue due to unavailability.
Maintenance Engineering
A staff function whose primary responsibility is to ensure
maintenance techniques are effective, equipment is designed and modified to
improve maintainability, ongoing maintenance technical problems are
investigated, and appropriate corrective and improvement actions are
taken. Maintenance engineering is often used interchangeably with plant
engineering or reliability engineering.
Maintenance Job Plans or Procedures
A job plan is a detailed description of how to implement or
undertake a maintenance activity. The term “procedure” is often used to
describe job plans, and is commonly used within CMMS’s to describe the
individual instructions combined to form a maintenance task.
Maintenance Labor Expenses
Direct pay for maintenance labor including overtime premium.
Maintenance Management
All activities of the management that determine the
maintenance objectives, strategies, and responsibilities, and implement them by
means, such as maintenance planning, maintenance control and supervision,
improvement of methods in the organization, including economical,
environmental, and safety aspects (UTEK, 13306:1998 E).
Maintenance Material Expenses
All materials, spare parts, supplies, etc., consumed for
maintaining equipment and facility including materials purchased for
maintenance by contractors and excluding materials for capital projects.
Maintenance Objectives
Targets assigned and accepted for maintenance activities.
Targets may include availability, cost reduction, product quality,
environmental preservation, safety, etc.
Maintenance Plan
Structured set of tasks that include the activities,
procedures, resources, and time scale required to carry out maintenance.
See Maintenance Schedule.
Maintenance Record
Part of maintenance documentation that contains all failures,
faults, and maintenance information related to an asset. This record may also
include maintenance cost, asset availability or uptime, and any other data
where relevant.
Maintenance/Reliability Engineers
Employees with primary functions of analyzing and resolving
maintenance problems, preventive and predictive maintenance, inspection and/or
equipment reliability support.