MAEng 713 MAINTENANCE ENGINNERING & QUALITY MGMT.

Department of Mechanical Vehicle Engineering

School of Engineering & Information Technology, Adama University

Course Number MAEng 713

Course Title MAINTENANCE ENGINNERING & QUALITY MGMT.

Degree Program Master

Module Manufacturing Engineering

Instructor

Credit 3

ECTS Credits 5

Contact Hours Lecture Tutorial Practice or Laboratory Home study

2 3 0 5

Course Objectives: This course has the objective of acquainting the student with advanced maintenance engineering skills and they will study the quality management principles. At the end of the course, the student will be able:

To Evaluate the Maintenance Department To schedule Preventive and Predictive Maintenance To integrate Maintenance with Quality management To work with Reengineering Maintenance To introduced with Computerized Maintenance Management Systems To Undertake proactive maintenance analyses To Assist in implementing the reliability strategy

Course Description: Introduction, Evaluation of Maintenance Department, Benchmarking, Preventive and Predictive Maintenance, Maintenance for Quality management, Reengineering Maintenance, Accounting and Inventory, Computerized Maintenance Management Systems, To Undertake proactive maintenance analyses, implementing the reliability strategy.

Course Outline: Unit I. Introduction

Introduction, reasons to set the maintenance department, elements of maintenance leadership, training of maintenance workers, attributes of world class maintenance, patterns in maintenance, alternative strategies to

management of maintenance and communication and delegation.

Unit II. Evaluation of Maintenance Department

Maintenance fitness questionnaire, questionnaires for top management, selling maintenance improvements to the whole organization, evaluation of maintenance budget for buildings and machinery and zero base maintenance budgeting reasons for maintenance resources.

Unit III. Benchmarking, Preventive and Predictive Maintenance

Maintenance information flow, maintenance bench marks, maintenance work order, recap sheet, evaluation of worker productivity, job duration, understanding preventive and predictive maintenance, examples, preventive maintenance strategy, life cycle costing, justification of expenditure in maintenance, installation and running of preventive maintenance systems, PM task list development, the science of customer service.

Unit IV. Maintenance for Quality management

Develop an understanding of the quality management system principles and the process model, Detailed examination and interpretation of the ISO9001:2000 elements, Continual effectiveness improvement focus and specific audit points, Auditing the documentation - the documented quality system audit, Audit sampling and development of the audit checklist, Conducting the audit, investigation, and psychology, Audit management - development of the activity/process based audit plan and schedule, Writing non-conformity statements and audit reports, Corrective action implementation, follow-up and closure process, Effectiveness evaluation of quality system performance based on audit results for management review, Audit skill development through individual and team workshops sessions.

Unit V. Reengineering Maintenance

Reengineering versus continuous improvement, contracting and outsourcing, total productive maintenance (TPM), measuring equipment effectiveness, installation of TPM, guaranteed maintainability, maintenance quality improvement, Deming’s fourteen points, ISO 9000 and its relation to maintenance, techniques for continuous improvement in maintenance, reliability centered maintenance, time management

Unit VI. Accounting and Inventory

Accounting issues, activity based costing, purchasing, inventory control, store keeping, auditing, maintenance scheduling, maintenance parts and part

vendors.

Unit VII. Computerized Maintenance Management Systems

Introduction, maintenance planning, return on investment from computer systems, design of maintenance management applications, applications of computerized maintenance management systems, internet and maintenance and special issues of maintenance such as factory and buildings.

Unit VIII. proactive maintenance analysesLiaise with operator, Analyze history, Undertake Failure Mode Effects Analysis (FMEA) (or similar), Undertake condition monitoring analysisUnit IX. implementing the reliability strategy

Arrange for schedules to be incorporated in relevant work plans, Identify training needs in discussion with relevant personnel, Assist personnel to develop required skills for inspections/servicing within scope of authority, Collect data/information as required by own work plan, Compare data/information with performance indicators, Recommend improvements to reliability strategy in accordance with procedures.

Pre-requisites:

Semester: 3rd

Status of Course: Compulsory

Teaching and Learning methods

Lectures with Topic Presentation Case study Educational visit

Assessment/ evaluation & Grading Systems

Topic presentation 20% Case study 30% Mid exam 20% Final Examination 30%.

Attendance Requirement:

Attendance Requirement:

Minimum of 80% attendance during lecture hours; and 100% attendance during presentation sessions and visits except

for some unprecedented mishaps.References:

1. Joel Levitt, The Handbook of Maintenance Management, Industrial Press Inc, 1997.

2. Joel Levitt, Managing Factory Maintenance, Industrial Press Inc, 1996.

3. Terry Wireman, Computerized Maintenance Management Systems, Industrial

Press Inc, 1994

4. P.Gopalakrishnan and A.K.Banergi, Maintenance and Spare Parts management, Prentice-Hall of India Ltd, 2002.