Principles and practices of

Maintenance planning
Reliability, Maintainability and Availability

Maintainabi
lity

Reliability

Availabil
ity

Maintenance planning

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Reliability
1.

Definition: The probability that the equipment/ system

performs its purpose adequately, for the period
intended, under the given operating conditions.

2.

A probability measure.
Adequate performance (Intended Function)
Duration of Performance (Time)
Operating condition specified

Reliability is the ability of an item to perform its

intended function under stated operation
conditions for a given period of time.
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Reliability is
Quantifiable

1.

Value between 0 and 1.

Essentially an engineering discipline.

2.

a formalized approach to achieve optimum product reliability

using management, engineering, mathematical and statistical
elements and concepts.

A design feature.
Not same as performance.

3.
4.

Performance relates to ability of of an item carrying out a

function.
Reliability is the repeatability of that function.

Not Quality

5.

Quality is the degree of conformance to specifications.

Maintenance planning

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Why Reliability is important?

Maintenance planning

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9/13/16

Why Reliability is important?

Reputation of the company/industry.
Customer satisfaction and customer requirement.
Warranty costs If a product fails to perform its
function within the warranty period, the replacement
and repair costs will negatively affect profits.
Repeat business Improved reliability has a positive
impact on future business.
Cost analysis

1.
2.
3.

4.
5.

6.
6

Life cycle cost analysis can prove that although the initial
cost of their product might be higher, the overall lifetime cost
is lower

Competitive advantage
Maintenance planning

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MEASURES OF RELIABILITY
1.

G P Kurien

These two measures are the mirror image of each other The
reliability will start at 1 and decay to approach 0 over time. The
cumulative distribution of failure will start at 0 (no failures)
and approach 1 as all the items fail over time. The slope of the
reliability curve at any time t is the failure rate at that point in
time. These measures give the overall reliability or failure at
time t

Maintenance planning

3.

This can be expressed as the cumulative distribution of failure

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2.

Reliability is the probability that a system will still be

functioning at time t.

Reliability Measurement
Mean time between failures (MTBF)
1. MTBF is the predicted elapsed time between
inherent failures of a system during operation.
2. MTBF can be calculated as the arithmetic mean
(average) time between failures of a system.
3. The MTBF is typically part of a model that assumes
the failed system is immediately repaired as a part
of a renewal process.
4. Eg. An aircraft operates for 9000hrs with 3 failures;
then:
MTBF = 90003=3000hrs
9

Maintenance planning

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Life Cycle cost based on Reliability

Cost

Ow
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t
Pur
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Unsc
d Ma
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Main eduled
Sche
tena
nce
Co st

Level of
Reliability

10

Maintenance planning

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COST EFFECTIVENESS OF RELIABLY

st

Cost

To

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ta

hi
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ne

o
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Level of
Reliability
1.

There are physical limits to the attainable reliability.

2.

Relatively small increments in the demand for reliability, increase the cost of
design and manufacture enormously and often place unworkable limitations on
the operating conditions.

3.

In many such cases, the cost of even a single failure is very high, as it takes
very long to set it right. Then, maintainability improvement has been found to
offer a substantially cheaper solution
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Maintenance planning

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Reliability and Redundancy

Redundancy is provision of backups that are
designed to come into use if their counterparts fail.
Types:

1.
2.

Load Sharing
Standby Redundancy

3.

12

Hot Stand by
Cold Stand by

Redundancy improves Reliability.

Maintenance planning

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Maintainability

Maintainability : Definition
The probability that the equipment will
be restored to certain specific conditions,
within a given period, when maintenance
action is taken, in accordance with
prescribed procedures and resources.
The aim of maintainability is to reduce down time of the
equipment

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Maintenance planning

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Maintainability
1.

2.

3.

15

A measure of the ease and rapidity with which a

system can be restored to operational status
following a failure.
Maintainability deals with duration of maintenance
outages or how long it takes to achieve (ease and
speed) the maintenance actions compared to a
datum.
This design features which ease maintenance as
well as repair, are a part of a new engineering
discipline called Maintainability.

Maintenance planning

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Design for
Maintainability
Maint.
in
minimu
m time
16

Maint.
in
minimu Safety
m
effort
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Design for Maintainability

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

17

Keep systems Simple .

Modular design and easily replaceable modules.
Provide scope for expansion and modification.
Standardize.
Label.- - Colour coding.
Document
Make wrong part difficult to fit.
Access is critical. Work space and accessibility.
Safety.
Predict failure/ warning systems.
Maintenance planning

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How to improve maintainability?

1.
2.

3.
4.
5.

18

Providing adequate accessibility, work space,

and work clearance.
Providing interchangeability of like components,
materials and parts within the system /
equipment.
Utilizing standard parts and items existing
within the inventories.
Limiting the number and variety of tools,
accessories and support equipment.
Insuring compatibility among system equipment
and facilities.
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Measures of Maintainability
Mean Time to Repair (MTTR)

1.

Mean of the active time required for repair of a

system/ equipment.
It does not include waiting time.

Mean Time Between Maintenance

(MTBM)

2.

19

Shows the frequency of maintenance.

Maintenance planning

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Maintenance Vs Maintainability
1.

2.
3.

4.
20

Maintenance is the action taken by the

user to retain/ restore the equipment or
system to its functional state.
Maintainability is the action taken at the
design and development stage.
Maintainability is a design function does
not improve performance of equipment
cannot be put into the equipment after it
is made.
Maintainability affects maintenance.
Maintenance planning

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Availability

Availability
1.

Indicates the proportion of the time that

the equipment is functional.

MTBF
A
MTBF MTTR

22

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Reliability Measurement
Mean time between failures (MTBF)
1. MTBF is the predicted elapsed time between
inherent failures of a system during operation.
2. MTBF can be calculated as the arithmetic mean
(average) time between failures of a system.
3. The MTBF is typically part of a model that assumes
the failed system is immediately repaired as a part
of a renewal process.
4. Eg. An aircraft operates for 9000hrs with 3 failures;
then:
MTBF = 90003=3000hrs
23

Maintenance planning

GP

9/13/16

Measures of Maintainability
Mean Time to Repair (MTTR)

1.

Mean of the active time required for repair of a

system/ equipment.
It does not include waiting time.

Mean Time Between Maintenance

(MTBM)

2.

24

Shows the frequency of maintenance.

Maintenance planning

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Example.
The details of failures and time to repair the
equipment each time for two equipments in a
period of one year are given below. Calculate
MTTR, MTBF, and Availability

1.

EQUIPMENT

Time to Repair (Days) during each failure

15

12

Solution
EQUIPMEN
T

MTTR
(Days)

MTBF
(Days)

AVAILABILITY

52

0.94

12

120

0.90

25

Maintenance planning

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FACTORS AFFECTING DOWNTIME

Everything must be done to reduce this time for which the
machine is down. The Elements are:
1.

Information and transit time: - This is the time required

for the information regarding a roadside (or operational)
failure of a machine to reach the appropriate repair agency
and the time to remove the failed equipment to the place of
repair (or alternatively, bring the repair technician to the
place of failure). In an industrial plant under one roof, this
is a small element. In a widely distributed organization like
Railways, Posts and Telegraphs, Transport Corporation
and the Army, this can be a major element.

2.

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ELEMENTS OF DOWNTIME (Continued)

2. Test and diagnosis time :- This is the time required
to locate or isolate the facility component at the
component level or at least at the assembly or subassembly level. In electronic equipment and complex
mechanical equipment with a lot of linkages, this can
be the largest element of repair time.
3. Removal time :- This is the time required to remove
the defective assembly and connected linkages,
controls or components, and includes the time for
removal of various other components to enable
access for the removal of the defective assembly or
sub-assembly for repair.
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Maintenance planning

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ELEMENTS OF DOWNTIME (Continued)

4.

Stripping time :- This is the time required for stripping the

assembly or sub-assembly to locate and reach its
component part which is actually defective or needs
adjustment.

5.

Repair time :- This the real repair time in which the

defective component is adjusted, such as by moving,
twisting, bending, tightening; or reconditioned such as, by
soldering, welding, painting or plating; or in some cases, the
component is removed and replaced by a serviceable one.

6.

Assembly time: - This is the reverse of the stripping time

mentioned above.

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Maintenance planning

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ELEMENTS OF DOWNTIME (Continued)

7.
8.
9.
10.

Assembly time: - This is the reverse of the stripping time

mentioned above.
Refit time: - This is the reverse of the removal time
mentioned earlier.
Test and check-out time : - This time is required to
ensure that the repair has been satisfactory.
Information and return time : - This is the reverse of
information and transit time mentioned above.

All these time elements are not always present in every single
repair action. Generally, one or more of the above
elements to time will always be present in every repair
action.
29

Maintenance planning

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The A B C Principle
1.
2.

30

A few account for the bulk of the

effect.
This is also true of the downtime
elements, i.e. a few of the downtime
elements account for the bulk of the
total downtime. It is useful to identify
this dominating element.

Maintenance planning

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9/13/16

How to reduce maintenance down time?

1.
2.
3.

4.
5.
6.

31

Rapid and positive detection of malfunction or

degradation.
Complete preparation (readiness) to begin
maintenance.
Rapid and positive localization of malfunctions to
the repair level for which skills, space and test
equipment are planned.
Ease of fault correction.
Rapid adjustment and calibration.
Rapid verification of correction.

Maintenance planning

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How Speedy Should Repairs Be?

Cost (Rs)
Minimum
Total Cost
of Repairs

Cost of Repair
Crews & Shops,
Spare Parts, and
Standby Machines
Cost of
Interruptions to
Production

0
Slow
32

Total Costs
of Repairs

Speed of Making Repairs

Maintenance planning

Fast
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9/13/16

Fast repair of the

malfunction equipment

An equipment
breakdown
should trigger
two actions

33

Development of a
program to eliminate
cause of the
malfunction and
need for such repairs
in the future
Maintenance planning

GP

9/13/16