Reliability and Maintenance AMIT 2K10/ME/022

Reliability:- Reliability can be described as a discipline related to the design, development, test, and manufacture of an item, so that it successfully performs a certain task, under specified conditions, for a certain length of time or number of cycle with a specified probability. Task: - The task is the job the equipment is designed to perform. Conditions: - The conditions are the environments that the equipment will experience at some time during its life which includes performing its task. Conditions include vibration, temperature, humidity, altitude, shock, sand and dust, etc. Time: - Time is the length of the mission. This can be measured in seconds, hours, days, years etc. and in cycles. Probability: - Probability is a numerical value that expresses the proportion, or the percent of the time the equipment will perform its mission successfully. It is called the probability of success, or the reliability for a mission of "t" hours, R (t). Reliability techniques can be applied to equipment that is being repaired or modified, and can also be applied to services that are performed. It is just as important that equipment being repaired be brought to the same level of reliability in new equipment. This involves maintainability.

Bathtub Curve

The bathtub curve gets this name from its shape; It is a graph of the failure rate over the life of a system. It is developed by AGREE (Advisory Group for the Reliability of Electronic Equipment) for studying the failure rate pattern over the life of electronic equipment. The horizontal scale o the bathtub curve is time, and the vertical scale is failure rate. The bathtub curve can be divided into three sections, the infant mortality stage, the useful life stage, and the wear out stage.

INFANT MORTALITY: - The infant mortality stage is so called because the failure rate is high just as it is for human beings. For equipment, the failure rate is high because of error made in the manufacturing process. The types of mistakes made during the manufacturing stage include the use of wrong parts during assembly, using parts that do not meet requirements, using unskilled and/or untrained operators to manufacture parts or build assemblies, purchasing; quality raw materials, using inadequate procedures, using the wrong tools, or making any kind of a mistakes that could impact the manufacturing and assembly process that could cause the system to fall in use.

To eliminate the infant mortality stage of the bathtub curve, error made in the manufacturing process must be eliminated. These errors are the symptom of the lack of quality. To improve quality requires a sincere effort to improve processes throughout the organization and a change on the cultural climate which must start at the top. It means that management must be involved in creating a vision of where the organization is headed be communicated throughout the organization and be shared by the workers. There must be plan that gets the organization working toward the vision, and workers must be empowered to make changes that improve the quality of the processes. For statistical purposes, the infant mortality stage of the bathtub curve can be described by the Weibull distribution.

USEFUL LIFE: - The middle part of the bathtub curve is the useful life stage. When the useful life is a horizontal line, the failures are for the system is constant. This line represents an average, implying that there are times when the failure rate is higher than the average and times when the failure rate is lower than the average. The instantaneous failure are is the failure rate at a specific point in time, and it is also called the hazard rate, h (t). The time at which the useful life ends is the system's life; it is the time when wear-out begins. The useful life stage of the bathtub curve can be described by the exponential distribution of the failure rate is constant, and by Weibull distribution if the failure rate is not constant. However, it should be noted that the Weibull can even be used when the failure rate is constant.

WEAR OUT: - The wear out stage of the bathtub curve an increasing failure rate and this means that the chance of failure increases. The wear-out phase can be delayed by a good preventive maintenance plan.

The wear out stage can be defined by the normal distribution or the Weibull distribution.

RELIABILITY DETERMINATION IN THE ADULT OR MATURE PHASE THE FAILURE RATE OF A COMPONENT OR SYSTEM IS CONSTANT. UNDER SUCH CONDITIONS THE TIME TO FAILURE FOLLOWS AN EXPONENTIAL LAW, AND THE PROBABILITY DENSITY FUNCTION OF EXPONENTIAL DISTRIBUTION IS AS GIVEN BELOW:

WHERE? DENOTES THE FAILURE RATE. THE MEAN TIME TO FAILURE MTTF FOR THE EXPONENTIAL DISTRIBUTION IS MTTF = 1 / ? IF THE FAILURE RATE IS CONSTANT, THE MTTF IS THE RECIPROCAL OF THE FAILURE RATE. FOR REPAIRABLE SYSTEM IT IS ALSO EQUAL TO MTBF. THE RELIABILITY AT TIME T, R(T), IS THE PROBABILITY OF THE PRODUCT LASTING UP TO AT LEAST TIME T. IT IS GIVEN BY

EXAMPLE: ASSUME WE HAVE AN AUTOMOBILE THAT IS OPERATING IN ITS MATURE PHASE AND HAS THE FOLLOWING FAILURE HISTORY: TIME TO FAILURE (HOURS): 100 800 1280 2600 THE MTBF IS GIVEN BY: [100+800+1280+2600] / 4 = 1195 HOURS/FAILURE THIS GIVES A CONSTANT FAILURE RATE OF: 1 / 1195 = 0.000836 FAILURES/HOUR.

WHAT RELIABILITY CAN BE EXPECTED FROM THE AUTOMOBILE AFTER 40, 200, 1000, AND 5000 HOURS?

T-HOURS

40

200 84.6%

1000 43.4%

5000 1.5%

RELIABILITY 97%

BEING ABLE TO PREDICT RELIABILITIES IS PARTICULARLY USEFUL IN TERMS OF MAINTENANCE SCHEDULING OF MACHINERY. ASSUME A MINIMUM RELIABILITY OF 0.9 CAN BE ACCEPTED FROM THE AUTOMOBILE, AT WHAT POINT WOULD A SERVICE BE REQUIRED?

THUS, THE AUTOMOBILE NEEDS SERVICING EVERY 126 HOURS TO KEEP A MINIMUM RELIABILITY OF 0.9

SYSTEM RELIABILITY SERIES SYSTEM : WHEN COMPONENTS ARE IN SERIES AND EACH COMPONENT HAS A RELIABILITY R I . IF ONE COMPONENT FAILS, THE SYSTEM FAILS.

THE OVERALL RELIABILITY OF A SERIES SYSTEM SHOWN ABOVE IS: R

AB

= R1 X R2 X R3

IF R1 = R2 = R3 = 0.95 RAB = R1 X R2 X R3 = 0.95 X 0.95 X 0.95 = 0.86 R TOTAL IS ALWAYS < THAN R1 OR R2 OR R3

PARALLEL SYSTEM : WHEN COMPONENTS ARE IN PARALLEL AND EACH COMPONENT HAS A RELIABILITY RI. IF ONE COMPONENT FAILS, THE SYSTEM DOES NOT FAIL.

RAB= 1 - PROBABILITY (1 & 2 BOTH FAIL) THE PROBABILITY OF 1 FAILING IS = (1 - R1 ) THE PROBABILITY OF 2 FAILING IS = (1 - R OVERALL RELIABILITY IS R IF R1= 0.9 AND R2 =0.8
AB 2

=1 - (1 - R

) (1 - R 2)

R R

AB

=1 - (1 - 0.9) (1 - 0.8) = 0.98 IS ALWAYS > THAN R1 OR R2

TOTAL

MAINTAINABILITY MAINTAINABILITY IS A DESIGN CHARACTERISTIC DEALING WITH THE EASE, ACCURACY, SAFETY, AND ECONOMY IN THE PERFORMANCE OF MAINTENANCE FUNCTIONS. IT MAY BE DEFINED IN SEVERAL WAYS:

THE PROBABILITY THAT AN ITEM WILL BE RESTORED WITHIN A GIVEN PERIOD OF TIME THE PROBABILITY THAT MAINTENANCE WILL NOT BE REQUIRED MORE THAN X TIMES A GIVEN PERIOD OF TIME

THE PROBABILITY THAT THE MAINTENANCE COST WILL NOT EXCEED Y RUPEES IN A GIVEN PERIOD OF TIME

MAINTAINABILITY IS THE EASE AND SPEED WITH WHICH ANY MAINTENANCE ACTIVITY CAN BE CARRIED OUT ON AN ITEM OF EQUIPMENT. IT MAY BE MEASURED BY MEAN TIME TO REPAIR. ONCE A PIECE OF EQUIPMENT HAS FAILED IT MUST BE POSSIBLE TO GET IT BACK INTO AN OPERATING CONDITION AS SOON AS POSSIBLE, THIS IS KNOWN AS MAINTAINABILITY . TO CALCULATE THE MAINTAINABILITY OR MEAN TIME TO REPAIR (MTTR) OF AN ITEM, THE TIME REQUIRED TO PERFORM EACH ANTICIPATED REPAIR TASK MUST BE WEIGHTED (MULTIPLIED) BY THE RELATIVE FREQUENCY WITH WHICH THAT TASK MUST BE PERFORMED (E.G. NO. OF TIMES PER YEAR).

MAINTENANCE CATEGORIES

CORRECTIVE

MAINTENANCE:

UNSCHEDULED

MAINTENANCE

TO

RESTORE A SYSTEM TO A SPECIFIED LEVEL OF PERFORMANCE

PREVENTIVE MAINTENANCE: SCHEDULED MAINTENANCE TO RETAIN A SYSTEM AT A SPECIFIED LEVEL OF PERFORMANCE

MEASURES OF MAINTAINABILITY MAINTENANCE ELAPSED-TIME FACTORS

MEAN CORRECTIVE MAINTENANCE TIME (MC) MEAN PREVENTIVE MAINTENANCE TIME (MP) MEAN ACTIVE MAINTENANCE TIME (MT = MC + MP) LOGISTIC DELAY TIME (LDT) ADMINISTRATIVE DELAY TIME (ADT) MAINTENANCE DOWN TIME (MDT=MT+LDT+ADT)

MAINTENANCE LABOUR-HOUR FACTORS

MAINTENANCE LABOR-HOURS PER CYCLE, ETC.

MAINTENANCE FREQUENCY FACTORS

MEAN TIME BETWEEN MAINTENANCE

MAINTENANCE COST FACTORS

MAINTENANCE COST PER SYSTEM OPERATING PERIOD, ETC.

AVAILABILITY THE ABILITY OF AN ITEM TO BE IN A STATE TO PERFORM A REQUIRED FUNCTION UNDER GIVEN CONDITIONS AT A GIVEN INSTANT OF TIME OR DURING A GIVEN TIME INTERVAL, ASSUMING THAT THE REQUIRED EXTERNAL RESOURCES ARE PROVIDED. AVAILABILITY AT ITS SIMPLEST LEVEL

AVAILABILITY = UPTIME / (DOWNTIME + UPTIME) THE TIME UNITS ARE GENERALLY HOURS AND THE TIME BASE IS 1 YEAR . FROM THE DESIGN AREA OF CONCERN THIS EQUATION TRANSLATES TO AVAILABILITY(INTRINSIC) A I = MTBF / (MTBF + MTTR) MTBF = MEAN TIME BETWEEN FAILURES MTTR = MEAN TIME TO REPAIR / MEAN TIME TO REPLACE. OPERATIONAL AVAILABILITY IS DEFINED DIFFERENTLY AVAILABILITY (OPERATIONAL) A O = MTBM/(MTBM+MDT). MTBM = MEAN TIME BETWEEN MAINTENANCE. MDT = MEAN DOWN TIME.

SYSTEM AVAILABILITY SYSTEM AVAILABILITY IS CALCULATED BY MODELING THE SYSTEM AS AN INTERCONNECTION OF PARTS IN SERIES AND PARALLEL. THE FOLLOWING RULES ARE USED TO DECIDE IF COMPONENTS SHOULD BE PLACED IN SERIES OR PARALLEL:

IF FAILURE OF A PART LEADS TO THE COMBINATION BECOMING INOPERABLE, THE TWO PARTS ARE CONSIDERED TO BE OPERATING IN SERIES

IF FAILURE OF A PART LEADS TO THE OTHER PART TAKING OVER THE OPERATIONS OF THE FAILED PART, THE TWO PARTS ARE CONSIDERED TO BE OPERATING IN PARALLEL.

THE CALCULATIONS OF SYSTEM AVAILABILITY ARE SIMILAR TO SYSTEM RELIABILITY. Objectives of Maintenance Management

The following are some of the objectives of maintenance management: I. Minimizing the loss of productive time because of equipment failure (i.e. minimizing idle time of equipment due to break down). II. Minimizing the repair time and repair cost. III. Minimizing the loss due to production stoppages. IV. Efficient use of maintenance personnel and equipments. V. Prolonging the life of capital assets by minimizing the rate of wear and tear. VI. To keep all productive assets in good working conditions. VII. To maximize efficiency and economy in production through optimum use of facilities. VIII. To minimize accidents through regular inspection and repair of safety devices. IX. To minimize the total maintenance cost which includes the cost of repair, cost of preventive maintenance and inventory carrying costs, due to spare parts inventory. X. To improve the quality of products and to improve productivity.

Types of Maintenance Planning

Single Cycle Plan A single cycle plan is the simplest form of maintenance planning. You create a single cycle plan (without a maintenance strategy) and define exactly one time-based or performance-based maintenance cycle, in which you specify the intervals at which the maintenance plan should be performed, for example, annually or every 100,000 km. You define the maintenance tasks to be performed by allocating a maintenance task list to the maintenance task list item of the single cycle plan. Time-Based Strategy Plans

With time-based maintenance plans, maintenance occurs at specific intervals, for example every two months, every six months, and so on. You create a strategy for time-based maintenance by maintaining maintenance packages and scheduling indicators. You define the planned intervals in maintenance packages and in task lists, you define which maintenance tasks should be performed. For this, you assign the task list operations to the strategy packages. Performance-Based Strategy Plans Performance-based strategy plans allow you to plan regular maintenance on the basis of counter readings maintained for measuring points assigned to pieces of equipment and functional locations. With performance-based/counter-based maintenance plans, maintenance occurs when the technical objects counter has reached a certain reading, for example every 100 operating hours. This may occur after two weeks or four weeks, depending on the counter reading at the time of scheduling, and the annual estimate that has been defined for the counter. You create a maintenance strategy in the same way as you would for a timebased maintenance plan by entering a single dimension (for example, tonnes produced, operating hours) and maintaining the scheduling indicator and maintenance packages. All the maintenance packages in the strategy share the same dimension. You define which maintenance tasks are to be performed and the frequency with which they are performed by allocating task list operations to the strategy packages. You then create a performance-based maintenance plan on the basis of the maintenance strategy. Multiple Counter Plans You create a multiple counter plan without a maintenance strategy. You have the following options:

Creating with a cycle set as a copy model for maintenance cycles You can delete unnecessary maintenance packages or add extra ones from the multiple counter plan.

Creating without a cycle set

If you have created the multiple counter plan without a cycle set, create maintenance cycles in the maintenance plan. You can assign counters with different dimensions to these cycles. You can also enter one time-based cycle in this maintenance plan.

Housekeeping refers to day-to-day cleanliness, tidiness and good order in all parts of the office. Good housekeeping provides a clean and pleasant working environment. It also helps prevent accidents in the workplace and aids the efficient operation of the office. Good housekeeping can usually be achieved by routine cleaning of the premises, proper storage of materials, periodic disposal of rubbish, regular maintenance of facilities and full staff co-operation.

5 S concepts
5S is literally five abbreviation of Japanese terms with 5 initials of S. These are (i)Seiri, (ii)Seiton, (iii) Seiso, (iv)Seiketsu, and (v) Shitsuke. Convenient translations to English, French and Swahili have similarly provided five initials of S. These are explained briefly below. (i) Sort, Sparer, Sasambua: Remove unused stuff from your venue of work; and reduce clutter (Removal organization) (ii) Set, Systmatiser, Seti: Organize everything needed in proper order for easy operation (orderliness) (iii) Shine, Salubrit, Safisha: Maintain high standard of cleanness (Cleanness) (iv) Standardize, Standardiser, Sanifisha: Set up the above three Ss as norms in every section of your place (Standardize) (v) Sustain, Se discipliner, Shikilia:

Train and maintain discipline of the personnel engaged (Discipline)