SHE Level 5
SCQF Credit Points 15.00
ECTS Credit Points 7.50
Module Code MMH723583
Module Leader Babakalli Alkali
School School of Computing, Engineering and Built Environment
Subject Mechanical Engineering
  • A (September start)
  • B (January start)
  • C (May start)

Summary of Content

This module examines the main methods for developing a modern maintenance programme for industrial plants. It provides a comprehensive understanding of theory and practice of reliability-centred maintenance and total productive maintenance strategies to achieve high plant availability, optimise on product quality, and address safety and environmental issues. The module will also consider shutdown and turnaround within maintenance of complex systems.


The teaching syllabus will cover the following areas: TPM The modern role of care and asset management through TPM and the TPM improvement plan. Planning and launching TPM. Lean maintenance. Maximising equipment effectiveness, and the implementation of autonomous maintenance. Equipment improvement, quality maintenance practices and fault analysis. The use of TPM /concepts (Fishborne diagram, OEE and 5S). Industrial visits to see how TPM techniques are implemented. RCM The changing world of maintenance and its evolutionary perspectives. RCM seven basic questions and the step-by-step procedure in conducting RCM analysis. The Plant Register and links with CMMS. The function and failure of complex systems. Failure mode and effect analysis (FMEA). Failure consequences analysis, maintenance and decision making. Failure data analysis and the use RCM Decision diagram. The nature of failure and technical history and implementing the RCM technique. Industrial visits.

Learning Outcomes

On completion of this module, the student should be able to:1. Critically evaluate a system and produce a TPM improvement plan2. Carry out an RCM analysis on equipment (Investigate how equipment operates and critically evaluate the equipment and come up with an improvement plan).3. Understand the importance of TPM and RCM strategies and how they are implemented in industrial plant.4. Understand the key steps which must be taken to implement the recommendations arising from RCM and TPM strategies.5. Understand the terms and definition of asset management standards 6. Use appropriate software to analyse equipment and systems, and support decision making in implementing maintenance strategies.

Teaching / Learning Strategy

Full-time This module will be taught by lectures, practicals, seminars, and software demonstrations, industrial visits and case studies. Lecture materials will be delivered within the first week of the three weeks cycle. Practical work will be undertaken over the two weeks and the module content will be delivered by a combination of notes, power point slides, a study pack and tutorials. Materials will be available on GCU Learn. Industrial visits: two visits will be arranged (for example to a power generating station and the National semiconductors) to demonstrate the importance of TPM and RCM strategies and how they are implemented in industry. Part-time In the first week lecture materials will be delivered by a series of lectures supported by a 3 hour tutorial session which will be used for data analysis. Students will be provided with a study pack to support their learning which will include; sample data and access to appropriate software Tutors will be available for consultation via e-mail, telephone and GCU Learn. Case studies and exercise materials will be available on GCU Learn. Distance Learning Students will be provided with study pack which will cover the syllabus materials. The module content will be delivered through the combination of notes, tutorials and practical sessions. Students will be provided with sample data and appropriate software. Tutors will be available for consultation via e-mail, telephone and GCU Learn.

Indicative Reading

-357 The student will be provided with course notes and directed to relevant web sites and technical publications. Relevant topics from the following books: 1. Lean maintenance, repair and overhaul Mandyam Srinivasan, Melissa R. Bowers, Kenneth Gilbert, McGraw-Hill (2014), ISBN: 9780071789943. 2. Assets maintenance management: A guide to developing strategies and improving performance, A Wilson (2007) 3. Total Productive Maintenance, S Borris, McGraw-Hill (2006). 4. Complex system Maintenance Handbook, KAH Kobbacy and DNP Murthy (2008) 5. The TPM Experience, P Willmott, Conference Communications (1998) 6. Reliability-Centred Maintenance, S Moubray, Butterworth and Heinemann (1997) 7. Reliability-Centred Maintenance: Management and Engineering Methods, Anderson, R,T and Neri, L (1990) 8. Introduction to Total Productive Maintenance, S Nakajima, Productivity Press (1988) Press (1988) 9. Introduction to IS55000 terms and definition and PAS 55 Asset Management Standards 10. TPM New Implementation Program in Fabrication and Assembly Industries, Edited by Kunio Shirose, JIPM Press (1996), ISBN 4-88956-902-2 11. Quick Changeover for Operators: The SMED System , Productivity Press (1996) ISBN 1 - 56372-125-7 12. Nolan, F., and Heap, H., "Reliability Centred Maintenance", National Technical Information Service Report, # A066-579, 1979.

Transferrable Skills

Critical thinking and problem solving. Critical analysis. Communication skills, written, oral and listening. Numeracy. Effective Information retrieval and research skills. Self confidence, self discipline & self reliance (independent working). Awareness of strengths and weaknesses. Creativity, innovation & independent thinking. Reliability, integrity, honesty and ethical awareness Enterprise/Business Skills Ability to prioritise tasks and time management (organising and planning work). Interpersonal skills, team working and leadership. Presentation skills. Commercial awareness

Module Structure

Activity Total Hours
Assessment (FT) 24.00
Lectures (FT) 24.00
Tutorials (FT) 8.00
Practicals (FT) 16.00
Independent Learning (FT) 78.00

Assessment Methods

Component Duration Weighting Threshold Description
Exam (Exams Office) 2.00 50.00 45% Exam Office
Coursework 1 n/a 25.00 45% Case Study (Total Productive Maintenance) (1500 words)
Coursework 2 n/a 25.00 45% Software Exercise (Reliability Centred Maintenance) (1500 words)