Availability Engineering and Management for Manufacturing Plant Performance

Preface. I. DEFINITION AND VALUE OF AVAILABILITY PERFORMANCE. Definition and Goals of Availability. Engineering and Management. Availability as a Core Subsystem of Plant and Business Performance. Attributes of Availability Performance. Summary. Bibliography. Financial Ramifications of Availability. Engineering and Management. Introduction. Consequences for Life-Cycle Cash Profiles. Payout and Discounted Cash-Flow Analysis. Return on Investment Analysis. The Break-Even Point and Operating Leverage Analysis. Summary. Bibliography. II. THE CONCEPTUAL DESIGN PHASE. Availability Engineering and Management and the Conceptual Design Phase. Introduction. Analyze Owner Needs. Establish Management Policies for Availability. Engineering and Management. Formulate Plant Operational Requirements. Formulate, Evaluate, and Select from Alternate Production Processes. Develop the Plant Conceptual Design. Develop the Availability Concept. Develop the Maintenance Operation Concept. Bibliography. PREPARATION FOR PROJECT EXECUTION. Introduction. The Challenges of a New Discipline. Summary of Requirements. Develop Availability Requirements for Contractor Screening, Selection, and Contract Documents. Assure Planning for Availability Tasks, Costs, Time, and Resources. Prepare to Monitor and Track Availability Engineering. Summary. Bibliography. III. BASIC DESIGN PHASE. Foundations to Maintain Integrity of the Availability Scheme. Introduction. Develop Availability-Centered Practices Control Documents. Develop Life-Cycle Improvement, Change and Data Management Functions and Systems. Bibliography. Development of the Plant as a System of Availability Parameters. Introduction. Identify, Gather, and Analyze Data for Availability Design. Develop Plant Logic Diagrams. Allocate Availability Parameters to Plant Logic Diagrams. The Production Process and Availability Parameters Compared. Bibliography. Develop Models to Design Profit-Effective Availability Performance. Introduction. Develop the Plant Availability Model. Develop the Plant Financial Model. Bibliography. Analysis of Failures and Development of Maintenance Strategy. Introduction. Availability-Centered Failure Modes, Effects, and Criticality Analysis. Maintenance Logic-Tree Analysis. Bibliography. Analysis and Optimization of Plant Availability Performance. Introduction. Evaluate and Optimize Plant Availability Performance. Assess Plant Layout for Maintainability. Bibliography. Traditional Plant Design during the Basic Design Phase. Introduction. Refine the Conceptual Design and Related Diagrams and Data. Determine and Develop the Process Control Strategy. Design the Instrumentation System. Develop Performance Specifications, and Select and Size Equipment. Size Lines. Determine Materials of Construction and Corrosion Allowances. Diagram, Analyze, and Determine Utility Needs. Develop the Plant Layout. Design Preliminary Piping Layout. Conduct Preliminary Hazard Evaluation. Identify and Begin Procurement of Long-Lead-Time Delivery Items. Develop Equipment Specifications. Develop Bulk Material Specifications. Final Comments for Availability Engineering and Management in the Basic Design Phase. Bibliography. IV. THE DETAILED DESIGN PHASE. Development of Maintenance Tasks and Procedures. Introduction. Maintenance Task Analysis. Needs Analysis and Design of Maintenance Instructions, Procedures, and Manuals. Evaluate Equipment for Maintainability from Human Factors Perspective. Bibiliography. Determination of Resource Levels for Operational Availability. Introduction. Determine the Human and Material Resources for Maintenance Operations. Detailed Design of Support Facilities and Equipment. Determine, Plan, and Develop the Training Program for Maintenance Personnel. Bibliography. Organization Design for Maintenance Operation Functions and Availability Management. Introduction. Analysis and Design of Maintenance Operation Functions. Organization Design for Availability Management. Bibliography. Traditional Plant Design During the Detailed Design Phase. Introduction. The Scope of the Traditional Detailed Design Phase. Detailed Design, Drawings, and Specifications. Detailed Safety and Hazards Analysis. Procure Engineered Items and Equipment. Procure Bulk Materials and Nonengineered Items. Expediting and Quality Assurance and Control. Needs Analysis and Design of Instructions, Procedures, and Manuals. Summary. Bibliography. V. THE CONSTRUCTION AND STARTUP PHASE. Construction and Planning for Startup. Introduction. Construction. Planning for Startup. Bibliography. Executing Plant Startup. Introduction. Mechanical and Electrical Completion and Precommissioning. Commissioning, Performance Testing,and Post-Commissioning. Summary. Bibliography. VI. COMMERCIAL OPERATIONS PHASE. Classic Cycles of Production System Management. Introduction. Classic Cycles of Production System Operation Management. The Strategic Cycle. The Research and Development Cycle. The Aggregate Planning Cycle. The Operating Budget Cycle. The Plant Level Production Planning and Resource Acquisition Cycle. The Production Cycle. The Maintenance Cycle. The Performance Testing and Evaluation Cycle. The Product, Production Process, and Plant Development Cycles. Bibliography. Availability Management in the Strategic Processes. Introduction. Analysis of Plant Availability. Research and Developmentfor Availability Performance. Availability Engineering andManagement in Cycles of Plant Development. Summary. Bibliography. Plant Capacity Matching and Budgeting Cycles in Availability Management. Introduction. Adjusting Availability to Match PlantProductive Capacity to Forecasted Market Demand. Adjusting Availability to MaximumShort-Term Financial Performance. Summary. Bibliography. Production Cycles and Evaluation in Availability Management. Introduction. Maintenance Operation Cycle Planning and Functioning. Test, Evaluation and Audit of the Availability Scheme as a System. Commercial Production without Availability Engineering and Management. Summary. Bibliography. Index.