Reliability and Maintenance

(MANE 4015 )
Instructor: Dr. Sayyed Ali Hosseini
Winter 2015
Lecture #1

What is Reliability?
The RELIABILITY of an item/system is the probability that the
item/system performs a specified function under specified
operational and environmental conditions at and throughout a
specified time.
Reliability is the capability to operate as intended, whenever
used, for as long as needed.
Reliability is performance over time, probability that
something will work when you want it to.

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Reliability Characteristics
Reliability

Is a time dependent concept

Can only be determined after an elapsed time
But can be predicted at any time.

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Reliability Measures
Availability
Mean Time to Failure (MTTF) or Mean Time Between Failures (MTBF)
Mean Time to Repair (MTTR)
What is failure?

Failure is the termination of the ability of an item to perform its

required function.
What is Maintainability?

The ability of an item, under stated conditions of use, to be retained

in, or restored to, a state in which it can perform its required
function(s), when maintenance is performed under stated conditions
and using prescribed procedures and resources. The time takes to
repair or maintain an item is expressed as Mean Time To Repair
(MTTR).
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Availability
The AVAILABILITY is the probability that a system is available for
use at a given time. In the other word, it is the probability that
the system is operational at any random time ( ) . The
availability is a function of reliability and maintainability.
Availability

Is used for repairable systems

When equipment is in a failed state it is no longer available for

work, and its reliability decreases. As the length of time in a
failed state (downtime ) increases, the maintainability of the
equipment decreases.

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MTTF or MTBF
Mean Time To Failure (MTTF) or Mean Time Between Failures
(MTBF) is the average expected time to failure (or between
failures)
Remarks
MTBF provides a reliability figure of merit for expected failure free operation
MTBF provides the basis for estimating the number of failures in a given period
of time
Even though an item may be discarded after failure and its mean life
characterized by MTTF, it may be meaningful to characterize the system
reliability in terms of MTBF if the system is restored after item failure.

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MTTR
Mean Time To Repair(MTTR) is the average expected time to
repair a damaged item after failure.

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Maintenance
Maintenance is a combination of all necessary actions for
retaining an item, or restoring it, to a serviceable condition.
It may include servicing, repair, modification, overhaul, inspection and
condition verification.
It increases the availability of a system.
It keeps systems equipment in working order.

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Some Important Questions

Why do we need maintenance?
What are the costs of doing maintenance?
What are the costs of not doing maintenance?
What are the benefits of maintenance?
How can maintenance increase profitability of company?

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Purpose of Maintenance
Attempt to maximize performance of production equipment efficiently and
regularly
Prevent breakdown or failures
Minimize production loss from failures
Increase reliability of the operating systems

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Principle Objectives in Maintenance

To achieve product quality and customer satisfaction through adjusted and
serviced equipment
Maximize useful life of equipment
Keep equipment safe and prevent safety hazards
Minimize frequency and severity of interruptions
Maximize production capacity through high utilization of facility

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Problems in Maintenance
Lack of management attention to maintenance
Little participation by accounting in analyzing and reporting costs
Difficulties in applying quantitative analysis
Difficulties in obtaining time and cost estimates for maintenance works
Difficulties in measuring performance
Why these problems exist?
Failure to develop written objectives and policy
Inadequate budgetary control
Inadequate control procedures for work order, service requests etc.
Infrequent use of standards
To control maintenance work
Absence of cost reports to aid maintenance planning and control system
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Different Types of Maintenance

Corrective or Breakdown maintenance

Scheduled maintenance

Preventive maintenance

Predictive (Condition-based) maintenance

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Corrective or Breakdown Maintenance

Corrective or Breakdown maintenance implies that repairs are
made after the equipment is failed and can not perform its
normal function anymore
Quite justified in small factories where:

Down times are non-critical and repair costs are less than other type of
maintenance

Financial justification for scheduling are not felt

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Disadvantages of Corrective Maintenance

Breakdown generally occurs at inappropriate times leading to poor and hurried
maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for both workers and machines
More spoilt materials
Direct loss of profit
Can not be employed for equipment regulated by statutory provisions e.g.
cranes, lift and hoists etc.

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Schedules Maintenance
Scheduled maintenance is a maintenance procedure that is
repeated on a regular basis. If scheduled maintenance is
neglected, breakdown and failure is likely to occur.
Scheduled Maintenance includes:
inspection
lubrication
repair and overhaul of equipment
Examples:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks etc.
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Preventive Maintenance
Prevention is better than Cure

Preventive Maintenance
locates weak spots of machinery and equipment
Provides them periodic/scheduled inspections and minor repairs to reduce the
danger of unanticipated breakdowns

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Advantages of Preventive Maintenance

Reduces break down and thereby down time
Less odd-time repair and reduces over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipment and spare parts
Better product quality and fewer reworks and scraps
Increases plant life
Increases chances to get production incentive bonus

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Predictive (Condition-Based) Maintenance

In predictive maintenance, machinery conditions are
periodically monitored and this enables the maintenance crews
to take timely actions, such as machine adjustment, repair or
overhaul. It makes use of human sense and other sensitive
instruments, such as audio gauge, vibration analyzer, amplitude
meter, pressure, temperature and resistance strain gauges etc.
Examples:
Unusual sounds coming out of a rotating equipment predicts a trouble.
An excessively hot electric cable predicts a trouble.
Simple hand touch can point out many unusual equipment conditions and thus
predicts a trouble.

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Cost

Failure Cost VS. Maintenance Commitment

Failure Cost

Maintenance Commitment

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Cost

Maintenance Cost VS. Maintenance Commitment

Maintenance Cost

Maintenance Commitment

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Total Maintenance Cost

Optimum

Cost

Total Maintenance Cost

Maintenance Cost
Failure Cost

Maintenance Commitment

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Emerging Strategies for Maintenance Management

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Conclusions
In general, reliability analysis and maintenance procedures are effective tools in
the hands of engineers to:
Predict the expected life of systems and their major components.
Predict the availability of systems
Predict the expected maintenance activities
Predict the support resources and spare parts required for effective operation
It must be noted that accurate prediction of the above mentioned items can only
be achieved by careful consideration of reliability and maintainability factors, most
effectively at the design stage.

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