CBM PdMexpense

Maintenance

ObsolescenceAQL

FMEA

mca

policy

The PdM Pocket Glossary

A Gu i d e to Co n d i t i o n Mo n i to r i n G A n d Pr e d i C t i v e MA i n t e n A n C e

a l l i e d r e l i a b i l i t y g r o u p

1s t e d i t i o n

Allied ReliAbility del ivers integrated Condit ioned Based Monitor ing (CBM) Technology Applicat ions, Consul t ing Services , and Processes as par t of an overal l equipment maintenance program to bui ld las t ing return on investment and impact on asset heal th . www.al l iedrel iabi l i ty.com

GPAllied is the most diverse manufactur ing and industr ia l re l iabi l i ty and operat ions consul t ing, t ra ining, and services company in the world. This divers i ty enables us to develop s ignif icant value proposi t ions for our c l ients by del iver ing solut ions across different industr ies , geographies , and—most important ly—across different aspects of an operat ion. www.gpal l ied.com

cARey RePAsz is a Business Unit Leader for All ied Rel iabi l i ty and serves as one of GPAll ied ’s Senior Instructors for the PM/PdM Best Pract ices t ra ining classes . In this role , he joint ly develops the curr iculum and shares his many case s tudies f rom his experiences with our c l ients in implementing best pract ices . Carey can also be found as a regular speaker a t CBM, PdM, and PM conferences within the maintenance and industr ia l sectors .

FunctionPdM GlossaryTarget Inventory Level

RELOCATEaction plan total cost

Backlog

Glossary

6

Action PlAnThe specific steps that must be taken to execute group decisions, including who does what by when.

Activity BAsed costingA method that allows an organization to determine the actual cost associated with each product and service produced by the organization based on their use of resources.

Adjustment (stock or inventory)(1) Minor tune-up action requiring hand tools, no parts and less than one half hour. Adjustments restore parts or assembly relationships such as tolerance, alignment, tension and tightness. (2) Write up, write down, of inventory as a result of a cycle count to adjust to the correct quantity.

AreA (or Zone) mAintenAnceMaintenance management scheme where area production cells are responsible for their own maintenance; denotes decentralized maintenance management.

AssetMaintenance: Lowest level of equipment that requires monitoring maintenance cost, equipment history, and reliability information, i.e. Motor, VFD, Pump, Gearbox, Fan, Fan coil, etc.

Asset vAlueThe book value of property owned and listed on the balance sheet.

Glossary

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BAcklogThe total number of estimated labor hours, by craft and priority, required to complete all identified but incomplete planned and scheduled work. Used as an index in determining how well maintenance is keeping up with the rate of work generation. Used also to help establish the proper size and composition of the work force. (See Open Work Order File.)

BAcklog PurgeThe evaluation of backlog work orders that are duplicates, now considered as unnecessary, orders that the work has been completed, but not completed in the CMMS. The evaluation is conducted with representatives of Production, Maintenance and Work Planning. The identified work orders are then completed or cancelled in the CMMS with comments noting the reason for removing the work order from the backlog.

BenchmArkingThe process of measuring products, services, and practices against those of leading companies. Comparing processes and performance with others.

Benefit trAcking A defined cost benefit from a work process that is tracked over a period of time.

Best in clAssA best-known example of performance in a particular operation. One needs to define both the class and the operation to avoid using the term loosely.

Glossary

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Bill of mAteriAls (1) All maintenance repairable or replaceable components for assets, assemblies and sub-assemblies. (2) Components that make up a Production assembly. The BOM is broken down into a Parent (the Main Piece of Equipment or the End Product of the manufacturing process) and its children (components that make up the equipment or end product).

BlAck Belt Six Sigma team leaders responsible for implementing process improvement projects within the business.

BrAinstormA basic problem-solving tool which uses the unevaluated ideas of group members to generate a list of possible options. Brainstorming can generate lists of (1) problems, (2) causes, (3) solutions and (4) actions, or any list where the creativity of the group would open up new possibilities.

BreAkdown mAintenAnceThe performance of maintenance to put failed equipment back on-line; the failure having occurred without early warning by the Preventive Maintenance System.

BreAk-in-workEmergency or urgent work that breaks into scheduled work. Urgent work may have enough lead-time to be put on the Daily Schedule. See Reactive Maintenance.

Business cycleA seemingly recurring change in general business activity alternating between low points and high points.

Glossary

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BudgetA plan that includes an estimate of future costs and revenues related to expected activities. The budget serves as a pattern for and a control over future operations. MRO budget: Covers items needed for the operation of a facility, but are not part of the finished product. Capital Budget: Acquisition of equipment that is capitalized as a depreciable asset on a company’s balance sheet. Materials Budget: Covers a firm’s need for production materials and components.

Business PlAnA statement of income projections, costs, and profits usually accompanied by budgets and a projected balance sheet as well as a cash flow statement.

Business Process reengineeringA management approach aiming at improvements by means of elevating efficiency and effectiveness of the processes that exist within and across organizations. The key to BPR is for organizations to look at their business processes from a “clean slate” perspective and determine how they can best construct these processes to improve how they conduct business.Business process reengineering is also known as BPR, Business Process Redesign, Business Transformation, or Business Process Change Management.

cAPitAl ProjectWork authorized by a capital fund authorization.

Glossary

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cAPitAl Assets (1) Items having a long life and requiring a relatively high dollar outlay for acquisition. (2) Items for which the cost is more properly chargeable to a capital account rather than to an operating expense account. (3) In addition to land and buildings, capital assets include other long-life depreciable items such as furniture, fixtures, and equipment required for the manufacture and distribution of products. Virtually all of today’s communication and building systems are grouped in the capital asset category.

certified suPPlierA status awarded to a supplier who consistently meets predetermined quality, cost, delivery, financial, and count objectives. Incoming inspection may not be required.

chAngeoverThe reconfiguration of an asset (e.g. dies, other hardware, and/or operating software), normally accomplished by production/operations personnel, to produce a different product.

chronic ProBlemOne which is characterized by long duration or frequent occurrence; one which we’ve chosen to live with and have accepted as a standard.

comPuteriZed mAintenAnce mAnAgement system

Computerized systems that schedule, track and monitor maintenance activities and provide cost, component item, tooling, personnel and other reporting data and history.

Glossary

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corrective ActionSolving problems; identifying and resolving problems.

corrective mAintenAnceMaintenance required to restore an item to a satisfactory condition, usually identified by PM activity. It can be emergency, urgent or planned work.

cost centerThe smallest segment of an organization for which costs are collected and formally reported, typically a department. The criteria in defining cost centers are that the cost be significant and that the area of responsibility be clearly defined. A cost center is not necessarily identical to a work center; normally a cost center encompasses more than one work center, but this may not always be the case.

cost of cAPitAlThe cost of maintaining a dollar of capital invested for a certain period, normally one year. This cost is normally expressed as a percentage and may be based on factors such as the average expected return on alternative investments and current bank interest rate for borrowing.

cost of goods soldAn accounting classification useful for determining the amount of direct materials, direct labor, and allocated overhead associated with the products sold during a given period of time.

cost of QuAlityThe measure of what it costs when we do our job right or when we do it wrong. It measures the cost of error as well as prevention and detection costs.

Glossary

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cost of Poor QuAlityThe cost associated with providing poor-quality products or services. There are four categories of costs: 1) Internal Failure Costs – Costs associated with defects found before the customer receives the product or service. 2) External Failure Costs—Costs associated with defects found after the customer receives the product or service. 3) Appraisal costs—Costs incurred to determine the degree of conformance to quality requirements. 4) Prevention Costs—Costs incurred to keep failure and appraisal costs to a minimum.

criticAl Asset Assets identified as critical by reliability engineering that, when unable to perform, cause severe consequences for the plant or facility and lead to a shutdown of production.

criticAl sPAresKey parts and/or components of an asset that need to be in stock or readily available because of the potential production, service and/or financial implications of an equipment failure requiring these materials.

deferred mAintenAnceMaintenance that can be postponed to some future date without further deterioration of equipment.

delPhi methodA quantitative Forecasting Technique where the opinions of experts are combined in a series of iterations. The result of each iteration is used to develop the next, so that convergence of the experts’ opinions is obtained.

desired PerformAnceThe level of performance acceptable to the owner or user of a physical asset or system.

Glossary

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downtimeTime when the machines in the plant are not producing because they are broken or down for repairs or other reasons (idle time).

emergency rePAirsImmediate repairs needed as a result of failure or stoppage of critical equipment during a scheduled operating period. Imminent danger to personnel and extensive further equipment damage as well as substantial production loss will result if equipment is not repaired immediately. Scheduled work must be interrupted and overtime, if needed, would be authorized in order to perform emergency repairs. Emergency repairs should be completed within one day after discovery.

engineering chAngeA revision to a Parts List, Bill of Materials, or Drawings, authorized by the engineering department. Changes are usually identified by a control number and are made for safety, cost reduction, or functionality reasons. In order to effectively implement engineering changes, all affected functions, such as materials, quality assurance, engineering, maintenance, tool room personnel, etc., should review and agree to the changes.

enterPrise Asset mAnAgement Information system that integrates all asset-related applications for an entire enterprise. Incorporates at least maintenance management, financial / budgeting, materials management, and reliability functionality.

Glossary

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enterPrise resource PlAnning Information system that integrates all related applications for an entire enterprise. Industry term for the broad set of activities, supported by multi-module application software to help manage the business, including (1) Product Planning; (2) Parts Purchasing; (3) Maintaining inventories; (4) Interacting with suppliers; (5) Providing customer service: and (6) Tracking orders.

environmentAl conseQuences The result of a failure mode and/or multiple failures that could have environmental consequences if it could breach any corporate, municipal, regional, national, district, or international environmental standard or regulation, which applies to the physical asset or system under consideration.

eQuiPment AuditInspection of mechanical and electrical components of equipment to detect out-of-specifications conditions in order to assess the adequacy of shop PM and general maintenance practices.

eQuiPment mAintenAnce PlAnA plan for maintaining equipment based on asset criticality and best life cycle costs.

eQuiPment rePAir historyThe chronological listing of significant repair actions performed on key units of equipment so that chronic, persistent problems can be identified and corrected. Historic repair actions also help guide current repairs. Used as the basis for developing a forecast. (See Forecasting.)

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eQuiPment modificAtionThe major changing of an existing unit of equipment or a facility from original design specification. This is not maintenance.

error ProofingDesigning a potential failure or cause of failure out of a product or process.

e-stoPEmergency Stop

exPenseFinancial Burden or outlay; cost.

externAl setuPSetup procedures that can be performed while equipment is in motion.

fAilure AnAlysis The act of determining the physical failure mechanism resulting in the functional failure of a component or equipment.

fAilure evAluAtion mode AnAlysis A procedure in which each potential failure mode in every sub-item of an item is analyzed to determine its effect on other sub-items and on the required function of each item.

fAilure finding tAsk Scheduled task that determines when a specific hidden failure has occurred.

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fAilure modeOne event causing a functional failure; the different ways a component can fail to perform as intended.

fAilure mode And effects AnAlysisIdentifying how equipment can fail, why it might fail, and how best to address potential failure; may or may not include criticality.

fAilure rePorting, AnAlysis, And corrective Action system

Assists in identifying and planning effective corrective actions.

function That which the owner or user of a physical asset or system wants it to do.

functionAl fAilureThe practice of grouping machines or activities by type of operation performed.

functionAl lAyoutThe practice of grouping machines or activities by type of operation performed.

functionAl mAintenAnceA type of maintenance in which the first-line maintenance supervisor is responsible for conducting a specific kind of maintenance, e.g., pump maintenance for the entire plant.

goAl The end towards which effort is directed. Goals are the steps directed towards the obtainment of an objective; as such, goals are more specific than objectives.

Glossary

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hidden fAilure Failure occurring that is not detectable by or evident to the operating crew.

hidden function Function that is not detectable by or evident to the operating crew.

initiAl cAPABility Level of performance for which a physical asset or system is capable of at the moment it enters service.

insPectionThe checking of equipment with the primary purpose of determining equipment reliability or repair needs and their relative urgency, often accompanied by cleaning, adjusting and minor component replacement.

instAllAtionThe installation of new or rebuilt equipment or relocation of fixed equipment.

internAl setuPSetup procedures that must be performed while machine is stopped.

iso9000 series stAndArdsA set of five individual but related international standards on quality management and quality assurance developed to help companies effectively document the quality system elements to be implemented to maintain an efficient quality system. The standards, initially published in 1987, are not specific to any particular industry, product, or service. The standards were developed by the International Standards Organization (ISO), a specialized international agency for standardization composed of the national standards bodies of 91 countries.

Glossary

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just-in-timeJIT is a system for producing and delivering the right items at the right time, in the right amounts. The key elements of Just-in-Time are Flow, Pull, Standard Work, and Takt Time. Implementing JIT requires most features of lean manufacturing.

key PerformAnce indicAtor Historical data that provides current status and trend information regarding the effectiveness of work processes, e.g. productivity/operating costs, maintenance labor and material costs, and performance/availability data.

lAy-uP mAintenAncePreventive Maintenance, usually non-intrusive, that is designed to ensure that key inventory items such as electric motors, gearboxes, bearings, belts, gaskets, pillow blocks, etc. are ready for use when issued. Lay up maintenance activities are often affected via a Preventive Maintenance Work Order.

life cycle costAlso known as the total cost of ownership which includes the costs associated with the acquisition, installation, usage, anticipated downtime, planned maintenance, and the disposal (if any) of the capital asset.

life cycle cost AnAlysisThe act of analyzing the total costs associated with the ownership of an asset. See Life Cycle Cost.

Glossary

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luBricAtion routeA dedicated path taken by a lubrication technician for periodic lubrication of equipment. A route should have a check sheet of all the equipment that describes the type of lubricant, number of lube points, type of fittings, when and how lubrication should be done and the oil change frequency.

mAin function The function constituting reasons why a physical asset or system is acquired by its owner or user.

mAintenAnceThe routine, recurring repair and upkeep required to keep facilities and equipment in a safe effective condition enabling it to be utilized at original design capacity and efficiency or some other level specified by management as the maintenance objective. Maintenance is normally an operating cost, although some projects, such as overhauls, performed with maintenance resources may be capitalized. The term maintenance means capacity assurance, to minimize downtime, increase production, and maximize profits.

mAintenAnce engineeringA staff effort aimed at ensuring that maintenance techniques are effective, that equipment is engineered for maximum maintainability, that persistent and chronic problems are discovered and corrective actions or modifications made. Responsible for review or the adequacy of repair materials used in maintenance; determination of critical parts and adequacy of stocking levels of replacement parts; monitoring the utilization of the maintenance work force; preparation of specifications for repair and new equipment selection, and other related similar actions.

Glossary

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mAintenAnce mAnAgement Management and control of maintenance functions.

mAintenAnce mAteriAl(s) The parts and supplies used to maintain and repair plant equipment and facilities.

mAintenAnce suPPlies Commonly used support items that aid in maintaining and repairing plant equipment and facilities.

mAintenAnce work The repair and upkeep of existing equipment, facilities, buildings or areas in accordance with current design specifications to keep them in a safe, effective condition while meeting their intended purposes.

mAintenAnce work order A formal document for controlling planned and scheduled work.

mAintenAnce work order system A means of communicating maintenance needs, planning, scheduling, controlling work and focusing field data to create information.

mAintenAnce work reQuest An informal document for requesting unscheduled or emergency work or a format for requesting all maintenance work. In the latter usage, once the MWR is approved, it becomes a MWO.

mAintenAnce, rePAir, And oPerAting suPPliesMaintenance materials purchased or in stores that are used for repair of or used in operating assets or facilities.

Glossary

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mAintenAnce, rePAir, And oPerAtions Fixing any sort of mechanical or electrical device should it become out of order or broken (repair) as well as performing the routine actions which keep the device in working order (maintenance) or prevent trouble from arising (preventive maintenance).

mAjor rePAirs Extensive, non-routine, scheduled repairs, requiring deliberate shutdown of equipment, the use of repair crew possibly covering several elapsed shifts, significant materials, rigging and, if needed, the use of lifting equipment.

meAn time Between fAilure An indicator of the overall reliability of an item. The mean time between failures of a repairable item that repaired and returned to use.

meAn time to fAilure An indicator of the overall reliability of an item. The mean time between failures of a non-repairable item.

meAn time to rePAirAn indicator of the overall maintainability of an item (includes impact of design, accessibility, and efficiency of the craftsperson effecting the repair). The mean time taken to repair failures of a repairable item.

meAsurABleCapable of being compared to a standard.

minor rePAirs Repairs usually performed by one man using hand tools, few parts and usually completed in less than one-half shift.

Glossary

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mixed model ProductionCapability to produce a variety of models, that in fact differ in labor and material content, on the same production line; allows for efficient utilization of resources while providing rapid response to marketplace demands.

multiPle fAilure Event occurring if a protected function fails while its protective device or protective system is in a failed state.

nAturAl work grouPA group of individuals from within a given department or function who develop and implement solutions to problems occurring within the jurisdiction of that department or function.

non-destructive testing Techniques intended to predict wear rate, state of deterioration or imminent equipment failure. Techniques include dye penetrant testing, magnetic particle inspection, ultrasonic thickness testing, and the like. May also include other predictive technologies such as vibration analysis, oil sampling, airborne ultrasonic’s, thermography, etc.

non-oPerAtionAl conseQuence Failure mode, with non operational consequences, that is not hidden, and does not have safety, environmental or operational consequences.

non-routine mAintenAnceMaintenance performed at irregular intervals with each job unique.

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non-vAlue Added Activities or actions taken that add no real value to the product or service making such activities or action a form of waste.

oBjective Something towards which effort is directed; an aim, goal or end of action. A strategic position to be attained or a purpose to be achieved. Objectives are statements of general plans towards which an organization’s efforts are directed.

oBsolescenceA state where materials are no longer usable due to a model or style change, technological development, deterioration, asset removal, inactivity, etc.

oil & gAs AnAlysisA predictive maintenance technique performed on transformer oil which can detect breakdown of the oil, contamination, insulation degradation and , arcing - to name a few.

oil AnAlysisA predictive maintenance technique used to determine the quality of the lubricant and/or the condition of the equipment being lubricated.

on-condition tAsk A scheduled task that is used to determine whether a potential failure has occurred.

one Point lessonA training device that covers one topic in under 15 minutes using simple text and graphics.

Glossary

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oPen work order fileA listing of all work orders currently open.

oPerAting context Circumstances in which a physical asset or system is expected to operate.

oPerAting exPensesProduction-related expenses incurred in conversion of raw materials into finished product (examples: power/fuels consumed in the process; consumable materials/parts such as additives, alloys, expendable tools/equipment; transportation of WIP through the manufacturing process; production labor).

oPerAting mAintenAnce Specific maintenance activities accomplished by production/operations personnel in direct support of Changeover activities (Examples: Cleaning; adjustment; lubrication; replacement of parts, asset setup, test asset operation prior to product run), or repair/replacement of production-related parts (knives, blades, belts) normally worn and requiring replacement during normal operations.

oPerAtionAl conseQuence Failure mode or multiple failures that has operational consequences if it could adversely affect the operational capability of a physical asset or system (output, product quality, customer service, military capability, or operating costs in addition to the cost of repair).

Glossary

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oPerAtor cAre Specific, detailed activities accomplished by operators to ensure proper asset operation, routinely check asset operating parameters (pressure, temperature, speed, etc), make necessary adjustments, lubricate, and make minor repairs incidental to the production process, and provide early detection of potential problems requiring maintenance support.

oPPortunity costThe return on capital that could have resulted had the capital been used for some purpose other than its present use. It usually refers to the best alternative use of the capital; at other times, however, to the average return from feasible alternatives.

oPtimiZAtion Achieving the best possible solution to a problem in terms of a specified objective function.

overAll eQuiPment effectiveness OEE is a metric used to monitor the effective use of equipment. It is obtained from the product of three ratios: 1. Availability ratio – Time for which equipment was available for operation. 2. Performance ratio – Rate of production divided by capacity of machine to produce. 3. Quality ratio – Quantity of ‘right the first time’ production divided by total production (‘right the first time’ + setoff + scrap).

overhAulsThe inspection, teardown and repair of a total unit of equipment to restore it to effective operating condition in accordance with current design specifications.

Glossary

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PAreto AnAlysisA problem-solving tool that helps arrange collected data so that comparisons can be made about problem causes. “Pareto’s Principle” states that results and causes of results are not equally distributed, but that 80% of the results come from 20% of the causes. Therefore, teams can focus their efforts on eliminating/reducing the 20% of the causes that will produce results. The “Pareto Chart” displays the data.

PArt numBerA number that serves to uniquely identify a component, product, or raw material.

PerformAnce indices Ratios, graphs, etc., which convey, at a glance, short-term accomplishments versus long-term trends.

Periodic mAintenAnceCyclical maintenance actions or component replacements carried out at known regular intervals. Usually intrusive, they are often based on repair history and regulated by current PM inspection results; includes inspecting, testing, partial dismantling, replacing consumables or complete equipment items, lubricating, cleaning and other work short of overhaul or renovation. This PM usually requires equipment to be scheduled out of service and may be done at intermediate intervals, usually ranging from monthly to annually.

PersonAl Protective eQuiPmentIndividual safety equipment.

Glossary

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PlAn, do, check, Act PLAN Senior management should use the visioning process in the context of its Business Plan. HP translates the Business Plans to action plans, meaningful to all levels of the organization. DO Answer the whats, hows, and whos for the total number of tiers for your organization; remember, the fewer the number of tiers, the better. Also, this is the time to bring management together and provide them with a basic understanding of HP mechanics. CHECK On a periodic basis, review the measurements and note what you’ve learned that can help in the future. ACT Make the necessary adjustments to plans and priorities in order to ensure the success of the strategy breakthroughs.

PlAnned/scheduled mAintenAnce workWork which, by virtue of cost, importance, extensive labor and materials required, etc., should be planned to ensure, when scheduled, that it can be completed with the least interruption to operations and the most efficient use of maintenance resources.

PolicyA definite course or method of action selected from among alternatives and in light of given conditions to aid managers to guide and determine present and future decisions about recurring situations or functions. Policies are broad direction of an authoritative nature laid down for the purpose of enabling all management decisions to be properly determined and adequately carried out in the successful attainment of the goals established.

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PotentiAl to fAilure curve Comparative charting of different approaches to maintenance and the incidence of failure. Graph that illustrates progress of detectable equipment defects and associated maintenance costs.

PotentiAl to fAilure intervAlInterval between the point at which a potential failure becomes detectable and the point at which it degrades into a functional failure. (Also known as ‘failure development period’ or ‘lead time to failure.’)

Predictive mAintenAnce The use of instruments and analysis to determine equipment condition in order to predict failure before it takes place so corrective maintenance can be done in a planned and scheduled fashion. Examples include vibration analysis, oil analysis, thermography, airborne ultrasonic’s, NDT, motor current signature analysis, trending of process parameters, etc.

Preventive AnAlysisThe tool associated with the principle of “Manage by Prevention.” By using this tool, problems can be brought out and dealt with before an activity is performed. Planning before the fact is always less expensive than reacting and patching after the fact.

Preventive mAintenAnce Time or cycle based actions performed to prevent system functional failure. This proactive maintenance type generally includes scheduled restoration and scheduled discard tasks.

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Preventive mAintenAnce overhAul And shutdown

Includes major work involving dismantling and inspecting equipment before breakdown occurs. It includes replacing or reconditioning equipment and components that have reached or are approaching their theoretical maximum life limit as determined by time or predictive techniques.

PriorityThe relative importance of a single job in relationship to other jobs, operational needs, safety, equipment condition, etc., and the time-frame within which the job should be done. Used primarily for Planned Work which subsequently will be scheduled.

Priority worksheetA problem-solving tool used to help in decision making; similar to Triadic Evaluation except that options are rated against several criteria.

ProActive mAintenAnceMaintenance activities designed to minimize the risk of failure of plant or equipment and keep equipment running as intended.

ProBlem/cAuse A serious condition or situation which prevents us from doing our job right the first time. The problem/cause is the difference between our current output and our desired output. It could be chronic or sporadic.

Procedure A series of steps followed in a regular definite order in which activities or tasks are to be carried out.

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ProcessThe flow of material in time and space. The accumulation of sub-processes or operations that transform material from raw material to finished product.

Process decision ProgrAm chArtA technique designed to help prepare contingency plans. The emphasis of the PDPC is to identify the consequential impact of failure on activity plans, and create appropriate contingency plans to limit risks. Process diagrams and planning tree diagrams are extended by a couple of levels when the PDPC is applied to the bottom level tasks on those diagrams.

Process kAiZenImprovements made at an individual process or in a specific area. Sometimes called “point kaizen”.

Protective device or Protective system Device or system intended to avoid, eliminate, or minimize consequences of failure in another system.

QuAlity function dePloymentA visual decision-making procedure for multi-skilled project teams which develops a common understanding of the voice of the customer and a consensus on the final engineering specifications of the product that has the commitment of the entire team. QFD integrates the perspectives of team members from different disciplines, ensures that their efforts are focused on resolving key trade-offs in a consistent manner against measurable performance targets for the product, and deploys these decisions through successive levels of detail. The use of QFD eliminates expensive backflows and rework as projects near launch.

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QuAlityMeeting the measurable requirements agreed upon with the customer.

Quick chAngeoverThe ability to change tooling and fixtures rapidly (usually minutes), so multiple products can be run on the same machine.

rAnking index mAintenAnce exPendituresA method for prioritizing maintenance work that takes both equipment criticality and work importance into account to arrive at an overall job priority.

rAsi/rAci chArtA matrix to show Responsibility, Accountability, Support/Consult, and Inform roles for each step of a work flow process.

reActive mAintenAnce Maintenance that takes place as a result of an equipment failure, imminent threat of failure or equipment performance issue.

reBuildThe repair of a component to restore it to serviceable condition in accordance with current design specifications.

reengineering The engine that drives Time-Based Competition. To gain speed, firms must apply the principles of reengineering to rethink and redesign every process and move it closer to the customer.

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reliABility The probability that an item can perform its intended function for a specified interval under stated conditions. (MIL-STD-721C)

reliABility centered mAintenAnceA process used to determine the maintenance requirements of physical assets in their present operating context.

reliABility engineeringThat set of design, development and manufacturing tasks by which reliability is achieved. See RELIABILITY. The main objectives of this strategic minded staff function performing reliability engineering are: (1) To apply engineering knowledge and specialist techniques to prevent or reduce the likelihood or frequency of failures. (2) To identify and correct the causes of failures that do occur. (3) To manage identified risk by determining the best ways of coping with (mitigating) the effects of failure if and when they do occur. (4) To apply methods for estimating the likely reliability of assets and for analyzing reliability data.

relocAteMove fixed equipment to a different stationary location.

rePAirRestoration of equipment to a condition equivalent to its original or designed capacity and efficiency by replacement of parts or after deterioration, overhaul to enable continued operation.

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rePAir history The chronological listing of significant repairs made on key units of equipment and the analysis of these repairs to help identify chronic, repetitive problems, failure trends and the life-span of critical components.

rePetitive mAintenAnceMaintenance jobs that have a known labor and material content and occur regularly (daily, weekly, etc.).

rePlAcement The process of removing badly worn parts (chains, belts, bearings, seals, gaskets, etc.) that are no longer capable of being adjusted. Scheduled replacement is performed to avoid costly repairs.

rePlAcement Asset vAlueThe current purchase price of the asset plus any costs necessary to prepare the asset for use.

rePlAcement mAteriAls stAndArdMaterials that can be used on more than one component or piece of equipment.

rePositionMovement of mobile equipment to a new working location.

reQuested mAintenAnce A request for maintenance service that did not emanate from the PM system, but did provide sufficient lead-time to allow proper, proactive, planning and scheduling.

Glossary

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reQuirement Documented and agreed upon standards that specify what is to be done and the expected outcome.

reQuirements AnAlysis The practice used to analyze supplier/customer relationships and stakeholder needs to make sure clear requirements have been communicated.

resource utiliZAtion The period of time in which the resource is adding value to the organization.

return on investment Typically used to determine the financial viability of a project and expressed as a percentage of the earnings produced by an asset to the amount invested in the asset. (Net Benefit / Total Cost).

right siZeMatching tooling and equipment to the job and space requirements of lean production.

root cAuse AnAlysisA systematic approach to problem solving that utilizes a set of techniques to identify physical, human, systemic and latent causal factors.

routine mAintenAncePrescribed services that are performed at a set frequency using standard procedures.

rulesStandards or guides for performing specific operations or limiting the activities of people.

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run-to-fAilure A failure management policy permitting a specific failure mode to occur without any attempt to anticipate or prevent it.

sAfety conseQuences The effects of a filure mode that results in death, injuring or near miss.

schedule comPliAnceThe percentage to which the weekly schedule was adhered to, calculated as the percentage of scheduled labor hours completed against total scheduled labor hours.

scheduled discArd A task designed to dispose of an item or component at a specified age limit, regardless of its condition.

scheduled mAintenAnceRepairs, rebuilds, overhauls and servicing that requires a minimum of 7 days to plan, obtain materials and schedule the availability of equipment and labor.

scheduled restorAtionA task designed to resotre the initial capability of an item or component at a specified age limit, regardless of its condition.

scheduled shutdown The scheduled removal of a facility from service to open, clean, inspect, repair, add, alter, close and test operating components; then return of the facility to service with a predetermined interval of time.

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36

scheduling Determination of the best time to perform a planned maintenance job to appreciate operational needs and the best use of maintenance resources. A system of accomplishing engineering and maintenance at a predetermined time that coincides as closely as possible with the date on which the work is required. It implies the orderly use of engineering and craft skills to accomplish the greatest good at any particular time. A joint function of Maintenance and Production.

scrAP Material outside of specifications and/or possessing characteristics that make retention or rework impractical. Unusable or unsellable items.

serviceABility Design characteristic that allows easy and efficient performance of service activities. A measure of the degree to which servicing of an item will be accomplished within a given time under specified conditions.

shutdownThe removal of a facility from service to open, clean, inspect, repair, add, alter, close and test operating components; then return of the facility to service with a predetermined interval of time.

simPlified fAilure modes And effects AnAlysis

A focused approach to identify likely failure modes and their associated risk to the business.

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37

single Point lesson A training device that covers one topic in under 15 minutes using simple text and graphics.

single-source suPPlier A company that is selected to provide 100% of the business requirement for a specific part or material, even though alternate suppliers may be available.

solution An activity that eliminates (or reduces the impact of) a root cause.

sPAre PArts list A list of recommended items and quantities that should be kept on hand or readily available to effectively maintain an asset.

sPeciAliZed sPAre PArts Parts that are used in and are unique to specific equipment components and equipment.

sPecificAtions Technical definition of configuration or performance requirements to meet intended utilization of equipment or materials.

sPorAdic ProBlemA problem that is characterized by only occasional occurrence or by scattered instances; also a problem that triggers alarm signals and requires a response.

stAndArd oPerAting ProcedureA written procedure used to ensure reasonable uniformity each time a significant task is performed.

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38

stAndArd rePlAcement PArtsParts that can be used on more than one component or piece of equipment. These parts may be carried in stock by suppliers for a number of users. Delivery lead times are predictable so stockouts can be managed.

stAndArd work A precise description of each work activity specifying cycle time, takt time, the work sequence of specific tasks, and the minimum inventory of parts on hand needed to conduct the activity.

stAndArds An established norm or requirement. It is usually a formal document that establishes uniform engineering or technical criteria, methods, processes and practices.

stAnding work orderA type of work order that is used to capture labor used on routine, repetitive actions where capture of history is not important. Examples include shop cleanup, toolbox meetings, etc.

steP definition A definition of each step of the workflow process.

stockoutA situation where material is unavailable within the agreed upon or required lead-time, thus preventing Stores from filling a mertial request.

stockout costsThe costs associated with a stockout. Those costs may include lost sales, backorder costs, expediting, and additional manufacturing and purchasing costs.

Glossary

39

storAgeThe retention of parts or products for future use or shipment.

storAge costsA subset of inventory carrying costs, including the cost of warehouse utilities, material handling personnel, equipment maintenance, building maintenance, and security personnel.

storesStored materials used for maintaining facilities, assets, operating supplies, and production materials. Room in which stored components, parts, assemblies, tools, fixtures, etc. are kept.

suB-AssemBly Logical group of assets that serves a common function within an assembly, i.e. Pump drive train, Fan drive train, Chilled water within AHU, steam system with AHU etc. A component assemblies that are part of a larger assembly.

suB-contrActingSending production or maintenance work to an external or third party service provider.

suB-oPtimiZAtion Situation where a process, procedure, or system yields less than the best possible outcome or output, caused by a lack of best possible coordination between different components, elements, parts, etc.

suBstitutionThe use of a non-primary product or component, normally when the primary item is not available.

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40

sunk cost The un-recovered balance of an investment. It is a cost, already paid, that is not relevant to the decision, concerning the future that is being made. Capital already invested that for some reason cannot be retrieved. A past cost that has no relevance with respect to future receipts and disbursements of a facility undergoing an economic study. This concept implies that since a past outlay is the same regardless of the alternative selected, it should not influence the choice between alternatives.

suPPort function(s) Functions which a physical asset or system has to fulfill while meeting its primary function, such as those needed to fulfill regulatory requirements and those which concern issues such as protection, control, containment, comfort, appearance, structural integrity, and energy efficiency.

symPtom Evidence that a problem/cause exists. This evidence needs to be clarified to determine the impact of the problem/cause.

system 1) An orderly, habitual or routine method, or methods, by which the regular activities of a part of a business, like maintenance, are executed. 2) A grouping of machines and components which work collaboratively to meet a specific function.

tArget A specific, quantitative measurement established in order to measure progress towards a goal.

Glossary

41

tArget costingDesigning a product to meet a specific objective. Target costing involves setting the planned selling price, subtracting the desired profit as well as marketing and distribution costs, leaving the required manufacturing or target cost.

tArget inventory levelIn a min-max inventory system, the equivalent of the maximum. The target inventory is equal to the order point plus a variable order quantity. It is often called an order-up-to inventory level and is used in a periodic review system.

technicAlly feAsiBle Task(s) physically possible to reduce or enable action to be taken to reduce the consequences of the associated failure mode to an extent that might be acceptable to the owner or user of the asset.

thermogrAPhy A predicitve maintenance method that detects infrared energy emitted from an object, converts it to temperature, and displays an image of the temperature distribution.

time And mAteriAl contrActs Provides payment for labor and overhead at a given rate per hour, plus the sales price of parts, supplies, and materials.

tolerAnceAllowable departure from a nominal value established by design engineers that is deemed acceptable for the functioning of the product or service over its life cycle.

Glossary

42

tolerAnce limits The upper and lower extreme values permitted by the tolerance. In work measurement, the limits between which a specified operation time value or other work unit will be expected to vary.

tool cAliBrAtion freQuency The recommended length of time between tool calibrations. It is normally expressed in days.

totAl costSum of all costs, regardless of which department or firm incurs them.

totAl inventory vAlue The average sum of all on-hand inventory from the first day to the last day of a given month, quarter or year.

totAl Productive mAintenAnce An approach to proactive maintenance that optimizes equipment effectiveness, eliminates breakdowns and promotes autonomous operator maintenance through day-to-day activities involving the total work force.

totAl QuAlity mAnAgementA business management strategy aimed at embedding awareness of quality in all organizational processes. TQM has been widely used in manufacturing, education, call centers, government, and service industries, as well as NASA space and science programs.

unPlAnned mAintenAnce Work completed with no job plan -- often used to describe breakdown, break-in or unscheduled work.

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ultrAsoundSimilar to vibration analysis, ultrasound is a sound wave or frequency generated by the release of energy. As a predictive maintenance technology, ultrasonic testing can be both passive, listening, or active by emitting an ultrasonic pulse and analyzing the echo return. Ultrasound is often used to find compressed air or steam leaks, or to identify structural defects within a material.

unscheduled rePAirs Non-emergency work that could result in becoming an emergency/breakdown if not addressed. Work that must be completed in the current scheduled week. A decision between production supervision and maintenance as to what work will be interrupted in the current week’s schedule to allow this work to take place.

vAluAtionThe technique of determining worth, typically of assets and inventory.

vAlue 1) Capability or quality provided to a customer for which they will pay a fair market price. 2) Performance of an asset that supports the organization’s strategic objectives.

vendor mAnAged inventory An arrangement where an outside vendor manages their customer’s inventory by counting, restocking, and invoicing parts, and performing other services normally done by the customer.

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44

viBrAtion AnAlysis This Predictive Maintenance technique is widely used to evaluate mechanical rotating equipment to determine if any undesirable changes are present that might give an early indication of imminent failure. Uses transducers to translate a vibration amplitude and frequency into electronic signals to determine the equipment’s actual condition. This may lead to the recommendation of a logical course of maintenance actions to correct the problem before secondary damage or catastrophic failure can occur. Additionally Vibration Analysis can be used for the modeling, prediction, measurement and analysis of structural dynamic response in design and root cause failure analysis. In design, vibration modeling and prediction is used to anticipate and avoid undesirable dynamic response. In root cause failure analysis it is used both to understand undesirable response and as a factor in determining true root cause.

wAll-to-wAll inventoryAn inventory management system in which material enters a plant and is processed through the plant into finished product without ever having entered a formal stock area.

wArehouse mAnAgement systemA key part of the supply chain and primarily aims to control the movement and storage of materials within a warehouse and process the associated transactions, including shipping, receiving, putaway and picking. The systems also direct and optimize stock putaway based on real-time information about the status of bin utilization.

weekly forecAstList of planned work selected from the backlog, forecasted to be scheduled during the following week.

Glossary

45

whAt if AnAlysisThe process of evaluating alternate strategies by answering the consequences of changes to forecasts, manufacturing plans, inventory levels, etc.

work orderAn order to the machine shop for tool manufacture or to the maintenance department for equipment maintenance or repair. Authorization to start work on maintenance.

work tyPe The types of work that make up the workload performed by Maintenance. Typical: PM, emergency, urgent and planned work.

workloAd The number of labor hours required to carry out a maintenance program.

world clAss The philosophy of being the best, the fastest, and the lowest cost producer of a product or service. It implies the constant improvement of offerings to remain an industry leader and provide the best choice for customers.

world clAss QuAlity A term used to indicate a standard of excellence: The best of the best.

yieldProduced product related to scheduled product –OR– percentage of a process or product that is free from defects.

P-F CurvePdM Acronymsfracas

fmecaCMMS hp

MRO

dmaic

Acronyms

48

AhmAsset Health Management

Ahm Asset Health Matrix (iReliability tool)

AltAccelerated Life Testing

AQlAcceptable Quality Level

BPrBusiness Process Reengineering

cBmCondition Based Maintenance

cBmCondition Based Monitoring

ciContinuous Improvement

cmCondition Monitoring

cmmsComputerized Maintenance Management System

cPiContinuous Performance Improvement

Acronyms

49

dfmDesign for Manufacturability

dfrDesign for Reliability

dfwDesign for Warranty

dmAicDefine, Measure, Analyze, Improve, Control

doeDesign of Experiments

dvtDesign Verification Test

eAmEnterprise Asset Management

eBom Equipment Bill of Materials

ecoEngineering Change Order

emPEquipment Maintenance Plan

eolEnd-of-Life

Acronyms

50

erPEnterprise Resource Planning

ertEarly Reliability Testing

etrEquipment Trouble Report

fArFailure Analysis Report or Request

fmAFailure Mode Analysis

fmeAFailure Mode and Effects Analysis

fmecAFailure Mode, Effects, and Criticality Analysis

frAcAsFailure Reporting, Analysis, and Corrective Action System

holHigh Operating Limit (also see UOL)

hPHorsepower

hZHertz

Acronyms

51

ir or irtInfrared Technology

jitJust-In-Time

khZKilohertz

kPiKey Performance Indicator

lccLife Cycle Cost

lccALife Cycle Cost Analysis

lolLower Operating Limit (see also COL)

m&oMaintenance & Operations

m&rMaintenance & Reliability

mcAMotor Circuit Analysis

mreMaintenance and Reliability Engineering

Acronyms

52

mroMaintenance, Repair, and Operations

mtBfMean Time Between Failure

mtBr Mean Time Between Repair

mtceMaintenance

mttfMean Time To Failure

mttrMean Time To Repair (or Restore)

mwoMaintenance Work Order

mwrMaintenance Work Request

ndtNon-Destructive Testing

nPfNo Problem Found

oAOil Analysis

Acronyms

53

oAcOperator Asset Care

ocOperator Care

odmOriginal Design Manufacturer

oeeOverall Equipment Effectiveness

oemOriginal Equipment Manufacturer

ogAOil & Gas Analysis

oPOperating Procedure

oPlOne Point Lesson

ortOn-Going Reliability Test

PcBPrinted Circuit Board

PdcAPlan, Do, Check, Act

Acronyms

54

PdmPredictive Maintenance

P-f curvePotential to Failure Curve

P-f intervAlPotential to Failure Interval

PlcProgrammable Logic Controller

PmPreventive Maintenance

Pme Preventive Maintenance Evaluation

PPePersonal Protective Equipment

PsiPounds Per Square Inch

PxPerformance Excellence

QAQuality Assurance

QcQuality Control

Acronyms

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QPmQuantitative Preventive Maintenance

r5Recognize, Rationalize, Ratify, Resolve, Realize

rAPReliability Assessment Process

rAtRapid Action Team

rAvReplacement Asset Value

rcARoot Cause Analysis

rcfARoot Cause Failure Analysis

rcmReliability Centered Maintenance

reReliability Engineering

recRoutine Equipment Care – aka OC (Operator Care), OAC (Operator Asset Care)

re-me Reliability Engineering – Maintenance Engineering (work stream)

Acronyms

56

rimeRanking Index for Maintenance Expenditures

rmeReliability & Maintenance Engineering

roAReturn on Assets

roArReturn on Asset Reliability

roiReturn on Investment

rPmReliability Planning and Management

rPPReliability Program Plan

rtfRun-to-Failure

skuStock Keeping Unit

soPStandard Operating Procedure

sPlSingle Point Lesson

teAmTotal Equipment Asset Management

Acronyms

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tPmTotal Productive Maintenance

tQmTotal Quality Management

twTime to Wearout

ueUltrasonic Evaluation; Ultrasonic Emissions

uolUpper Operating Limit (also see HOL)

utUltrasonic testing

vVolt

woWork Order

wrWork Request

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From the reliability professionals at

4200 Faber Place DriveNorth Charleston, SC 29405

843.414.5760 | info@alliedreliabilitygroup.com | alliedreliabilitygroup.com

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