22/03/1431

ENGINEERING RELIABILITY

Dr. Ashraf S. Youssef

Assistant Professor,
Professor QMS Consultant
Industrial Engineering Dept.
Fayoum University

Course Introduction
„ Welcome!
„ Instructor introduction.
„ Student introduction.

„ TEXT BOOK
„ Reliability Engineering: Fundamental and
Applications, R. Ramakumar, Prentice Hall
International, 1993.

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Learning Objectives
„ Understand Reliabilityy fundamentals.
„ Relation Between Quality and Reliability.
„ Modeling Approach for Parallel and Serial
Systems.
„ Equipment Survival.
„ Reliability Prediction Methods.
Methods
„ Reliability Testing.
„ Maintainability Concept and Measure.
„ Integrated Logistic Support.
„ Replacement Models

Our Objective

You Enjoy While You

Learn

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Part ONE

Introduction to
Reliability Engineering

Definitions (1/2)

Reliability Quality maintained over time

Quality Meeting customer requirements

Quality
Monitoring quality characteristics
Control

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Definitions (2/2)

Quality Set milestones to check quality in

Assurance progress

Use the proper gages and

Quality
measuring devices and procedures
Auditing
to check quality (Use sampling)
Set necessary conditions for all
TQM production steps from entering
raw materials to finish products

Relation between
QC, QA, & TQM
TQM … Organization
Difficult Time Soft Employees
Leadership
Culture
Business Results
QA … Business Processes
Procedures
Policies Responsibilities

SPC … Product
Off-line
On-line

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Quality Dimensions
Conformance Durability
Reliability Serviceability
Features
Performance Perceived
Quality
Product

Source: Total quality and organization development by Lindsay and Petrick

Part TWO

Discrete Random Variables

and
P b bilit Distributions
Probability Di t ib ti

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Statistical Overview
P
Population
l ti
A large No. of N
Mean = µ
Standard Deviation = σ

Sample
A small No. of n X
Sample Mean =
Sample Standard
Deviation = s

Descriptive Statistics
„ Centrality Measures
¾ Mode
¾ Median
¾ Mean
„ Dispersion Measures
¾ Range
¾ Variance
¾ Standard Deviation
¾ Coefficient of Variation

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Accuracy & Precision

____________ ____________ ____________ ____________

____________ ____________ ____________ ____________

Example:
Histogram
Freq.

Weight
6 9 13 17 21 25

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Bernoulli Distribution
Set 1
Set 2

Those two sets are:

1. Mutually exclusive
2. Union of the 2 sets represents the random space
Probability Calculations
1. Probability of occurrence in the set 1 = P
2. Probability of occurrence in the set 2 = q
1, if x є s1
P.d.f (X=x) =
0, if x є s2

Binomial Distribution (1/2)

„ Iss a repeating
epeat g Bernoulli
e ou n ttimes es a
and
d measuring
easu g outco
outcomes.
es
The trials are:
„ Independent, each trial has only two outcomes.

P.d.f
P ( X = x) = ( nx ) p x q n − x
Where P is the prob. Of outcome of the set 1
Where q is the prob. Of outcome of the set 2

X is the variable observed and related to p

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Binomial Distribution (2/2)

If x is a binomial random variable with parameters p
and n then:

μ = E ( x ) = np
σ = V ( x) = np(1 − p)
2

Example:

„ Each sample of air has a 10% of chance of containing a

particular molecule. Assume the samples are independent
with regard to the presence of the rare molecule. Find the
probability that in the next 18 samples, exactly 2 contains
the rare molecule. Also, calculate the expected value of
the random variable x and the variance
variance.

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Hyper Geometric Dist (1/2).

„ Is a special
p case from binomial.
„ The population N is known

P.d.f N −M
( x )( n − x )
M
P ( X = x) =
( nN )
Where N= size of population, n = Sample
size, M is the objects that classified as
successes, x = no. of success in the
sample.

Hyper Geometric Dist (2/2).

„ Let p=M/N
p /

μ = E ( x ) = np
and
N − n
σ 2
= V ( x ) = np (1 − p )( )
N −1

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Example:

„ A batch parts contains 100 parts from a local suppliers of

a tubing and 200 parts from a supplier of tubing in the
next state. If four parts are selected, at random without
replacement, what is the probability they are from the
local supplier, and what is the probability that at least one
part in the sample is from the local supplier?

Poisson Distribution (1/2)

„ Let x is a no
no. of occurrences of a random
variable with a certain rate of occurrence
(‫)ג‬ −λ
P.d.f e λ x
P ( X = x) =
x!
Where x = 0,1,2,……
Binomial Can be approximated to Poisson if,
n is very large and p is close to zero, ‫=ג‬np

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Poisson Distribution (2/2)

„If X is a Poisson random variable with
parameter (‫)ג‬
Then λ

μ = E (x) = λ
and
σ 2
= V (x) = λ

Example:

„ For the case of the thin copper wire, suppose that the
number of flaws a Poisson distribution with a mean of 2.3
flaws per millimeter. Determine the probability of exactly
2 flaws in 1 millimeter wires.
„ Determine the probability of 10 flaws in 5 millimeters of
wire.
i

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Uniform Distribution
„ Say, x1, x2, ….., xn has equal probability
Say
P.d.f
P( X = x ) = 1 / n
i
Ex:
R={0 1 2 3 4 5 6 7 8 9}
R={0,1,2,3,4,5,6,7,8,9}
f(x) = 0.1
E(x) = (a+b)/2
V(x) = ((b-a+1)2 – 1)/12

Example:

„ Let the random variable X denote the number of the 48

voice lines that are in use at a particular time. Assume
that X is a discrete uniform random variable with a range
of 0 to 48. calculate the mean and the variance of X.

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Part Three

Continuous Random
Variables and
Probability Distributions

Uniform Distribution
„ A continuous random variable X with probability
density function. It uses to approximate several
processes when could be boundaries and has
equal chance.
1
f ( x) =
b−a
E(x) = (a+b)/2
V(x) = (b-a)2 /12

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Example
„ Let the continuous random variable X denote
the current measured in a thin copper wire in
milliamperes. Assume that the range of X is
[0,20 mA]. What is the probability that a
measurement of current is between 5 and 10
milliamperes? Also, calculate the standard
deviation of X.

Exponential Distribution
„ A continuous random variable X for time between
events to happen.

f ( x ) = λ e − λx
Where ‫> ג‬0, and x>=0
E(x) = 1/‫ג‬
V(x) = 1/‫ ג‬2

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Example
„ In a large corporate computer network, user
log-ons to the system can be modeled as a
Poisson process with a mean of 25 log-ons
per hour. What is the probability that there
are no log-ons in an interval of 6 minutes.

Normal Distribution (1/3)

„ Any natural behavior with out any control from
human takes a normal distribution.

− ( x− μ )2
1
f ( x) =
2
2σ
e
2πσ

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Normal Distribution (2/3)

Standard Deviation (σ )

Mean ( μ )

99.7 Percent

95 Percent

68 Percent

Y - 3s Y -2 s Y-s Y +3s
Y Y+s Y +2s

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Reliability

Monitoring a quality
attributes over a specific
period
i d off time
ti

System Reliability

System will perform at a

specific level of a quality
f a specified
for ifi d length.
l th

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Why Monitoring Reliability?

1. B tt resource allocation
Better ll ti tto fi
fix b
breakdowns.
kd
2. Design an efficient preventive maintenance
plan from failure analysis.
3. Monitor stocks and inventory levels (spare
parts).
parts)
4. Aggregate planning (Demand for full
product + spare parts)

To Implement Reliability
1. Conceptual
C t l design
d i (Make
(M k sure allll
components of systems will meet
requirements)
2. Detailed/final design. Can you measure or
predict reliability?
3. Planning for manufacturing.
4. Effects of operating & maintenance period.

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Cost of Reliability
 

     $ F irs t Co s t (P u r c ha s e )

  T o ta l   C o s t

  O p tim u m  C o s t

  O pe r a tin g  &  M ain te n a n ce  C o st

R e lia bility

  F a ilu re  r a te

Failure Analysis
1. Failure rate, no. of components failing within
specified period.
2. Maintenance: Preventive maintenance (PM),
Corrective maintenance (CM).
3. Catastrophic failure: wait till all component, or
critical component
p failed.
4. Availability: Probability that system is operable.
5. Mean time between failure (MTBF).
Failure (n) Failure (n+1)
6. Mean time to fail (MTTF) T=0 MTTF
T=t1
This is the first failure
7. Mean time to repair (MTTR)

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Hazard Function

f (t )
λ (t ) =
R (t )

Where f(t) is a failure function, and

R(t) is the reliability function

Hazard Rate (Bath tub Behavior)

‫(ג‬t)

Region I Region II Region III

t
t1 t2

Region I: Debugging region (warm up period)

Region II: Operating region
Region III: Burning out (wearing out)

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Types of Reliability Systems (1/3)

‫(ג‬t)

Digital Systems: Short period of warm up

Long period of Operating
Short period of burning out

Types of Reliability Systems (2/3)

‫(ג‬t)

Mechanical and Hydraulic System

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Types of Reliability Systems (3/3)

‫(ג‬t)

Administrative System (Governance Systems)

In this system, No quality Management System

Example
If , The failure densityy function f(t)
( ) = 0.25 – ((0.25/8)t,
) t>=0
Find all other reliability functions.

Solution:

1 Q(t)
1. Q( ) = 0.25t
0 25 – (0
(0.25/16)t
25/16) 2
2. R(t) = 1 – Q(t)
3. ‫(ג‬t) = f(t)/R(t)

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Mean Time To Failure (MTTF)

∞
MTTF = ∫ R ( t ) dt
0
F(t)

Example: 0.25

If, f(t)=0.25-(0.25/8)t, find MTTF.

R(t) = 1- Q(t) 8
MTTF = ∫ R ( t ) dt
0
8
t

Reliability & Maintenance

1. Applying corrective maintenance in region I

2. Applying preventive maintenance in region
II (Increase period (t1 – t2), and reduce ‫)ג‬
3. Applying both corrective & preventive
maintenance in region III (reducing slope by
using PM), In this region CM dominates PM.

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System Reliability

Any system with n components could be modeled

(flow charted) as:
1. Series components
2. Parallel components
3. Hybrid components.

Series Components (1/2)

A 1 2 n B

In series system, any component fails, will cause a

system failure

System reliability = System Success.

Rs = P(x1) * P(x2)……..* P(xn)

n n
Rs = ∏
i =1
p ( xi ) = ∏
i =1
Ri

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Series Components (2/2)

Examples:
1. Taking 3 courses in one area and each one depends
on the other (prerequisite).
2. Car has six major subsystems, four of them are series.
I. Gas system
II. Engine system
III. Transmission system
IV. Axes
System Failure = Qs = 1 - Rs
n
Qs = 1− ∏
i =1
Ri

Example:
A 1 2 3 B

For the previous system, if you know that,R1=0.9,

R2=0.8, and R3=0.7. Calculate Rs
Rs=0.9 * 0.8 * 0.7 = 0.504

In a series system, Rs is getting smaller than the

components reliability Ri

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Series System Advantages

There are many highly reliable series systems in

use that offer a number of advantages:
1. Use a minimum number of parts
2. Consumes minimum power
3. Takes up a minimum of space and adds a
minimum weight.

Parallel Components
1

A 2 B

n
In parallel system, all components fail, will cause a
system failure

System reliability = 1- [System failure].

R s = 1 − [1 − R 1 ] × [1 − R 2 ] × ....[ 1 − R n ]

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Example:
1

A 2 B

3
For the previous system, if you know that,R1=0.9,
R2=0.8, and R3=0.7. Calculate Rs
Rs=1- (1-0.9) * (1-0.8) * (1-0.7) = 0.994

In a parallel system, Rs is getting greater than the

components reliability Ri

Example:
L t each
Let h componentt ffor parallel
ll l
system has a reliability Ri = 0.7.
R
Find, reliability of system when 1.02
1
0.98

n=2, n=3, n=4, and n=5. 0.96

0.94
0 92
0.92

Conclusion 0.9
0 1 2 3 4 5

The first redundant unit

will add to reliability

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Parallel System disadvantages

This can lead to significant increases in:

1. Costs
2. Power consumption
3. Weight
4. Space requirements

Hybrid Components

1 2 5
A 4 5 B

3 5

R1 through R5 are the reliability values for subsystems

1 through 5:
R1=0.98, R2=0.98, R3=0.92, R4=0.999, and R5=0.90
Determine the Rsys.

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Stand-by-System

You need to switch to the redundant unit, when

the main component fails. A
1. A is an operational unit
2. B is a stand byy unit B
3. Develop a switching concept and assume
that it is reliable for smooth transition.

What is Maintenance?
BS 3811:1974
Maintenance is defined as: The work under taken
in order to keep or restore a facility to an
acceptable standard level.
„ Or

The combination of activities by which a facility is

kept in, or restored to, a state in which it can
perform its acceptable standard.

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Maintenance Policies
Maintenance Policies
“To Keep” “To Restore”
Planned Maintenance Unplanned Maintenance

- Time Based Maintenance - Corrective Maintenance

- Condition Based Maintenance - Run To Failure
- Risk Based Maintenance - Emergency Maintenance
- Break down Maintenance

Preventive Maintenance
Time-based PM
•Pure time )calendar) based: Weekly, monthly, annually, etc.
•Used (running) time based: 1000 km, 1000 RH, 3000 RH,
etc.
Preventive maintenance actions usually include:
1. Cleaning 2. Lubricating
3. Changing filters
4. Replacing worn parts at prescribed times
5. Inspecting to find and eliminate potential failures.

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Predictive Maintenance
(Condition-based)
(Condition based) Maintenance
By monitoring key equipment parameters "Off-line or
On-line“

¾Vibration analysis
¾Oil analysis
¾Wear analysis
¾Noise analysis
¾Temperature analysis
¾Pressure analysis
¾Quality analysis
¾Efficiency analysis, etc.

Corrective Maintenance
Corrective maintenance consists of all actions required to
retain a unit in its functional state after a failure occurs.
Preventive Maintenance actions usually include:
1. Preparation, obtaining the proper tools and test
equipment, traveling,… etc.
2. Active maintenance, locating the cause of the
failure, disassembling the unit, repairing the
fault, reassembling the unit, checking out.
3. Delays, waiting for spares,… etc.

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Corrective versus preventive

Maintenance
Corrective Maintenance Preventive Maintenance

MTTR, MTBF MTBP

Affected by reliability, High Reduce the probability of

reliability unit , Low failure
frequently of CM

Increase Unit reliability

Done after unit fails

Maintainability
It measures a unit’s
unit s ability to be retained in, or restored to,
specific conditions. For maintainability calculations, the following
assumptions are made:

1. Maintenance is performed by qualified personnel.

2
2. Maintenance personnel have access to resource required
for maintenance and repair.
3. Maintenance is performed according to prescribed
procedures.

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Availability
Is the p
probabilityy that a unit will be readyy for use at a stated
instant of time or over stated period of time, based on the
combined aspects of reliability and maintainability.

The reliability engineers must consider several elements in

addition to reliability and maintainability,
maintainability including
1. System type.
2. Typical product use.
Downtime. MTBF
3. Avail =
MTBF + MTTR

According to Maintenance
Information

(1) (2) (3)

Complete Incomplete Without
Information information information
Planned PM Planned CM Unplanned CM
70 % 20% ( Emergency)
(or E )
10%

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MMH Distribution in Industries

Maintenance Works

Planned Unplanned
≥ 70 % ≤ 30 %

PM Repairs Minor repairs Repairs

≥ 45 % ≥ 25 % ≤ 20 % ≤ 10 %

Maintenance Process (1/2)

Experience

Maintenance
Planner

Tools Information

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Maintenance Process (2/2)

Experience: Information: Tools:

•Technical •Catalog •Computer programs
•Planning •Forms / reports •International
•Analysis •Data collection standards
•Decision making •PM levels •Management tools,
•Problem solving •Job plans for each etc.
•Working conditions, PM level
etc.
t •Resources
R
•Cost rates
•CM work orders
•Failure analysis, etc.

Maintenance Cost
¾Maintenance costs are a major part of the total operating costs
off allll manufacturing
f t i or production
d ti plants.
l t
¾Depending on the specific industry, maintenance costs can
represent between 15% and 40% of the costs of goods
produced.
¾For example in food related industries, the average maintenance
cost represents about 15% of the cost of goods produced; while
in iron and steel,, pulp
p p and p
paper
p and other heavy y industries
maintenance represents up to 40% of the total production costs.
¾US industry spends more than $200 billion dollars each year on
maintenance of plant equipment and facilities,

Maintenance Cost: 10 – 25 % &

Spare parts Cost: 3 – 10 %

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Maintenance Cost Elements (1/2)

Directt cost:
Di t
Spare parts & supplies cost
Labor cost
Contract cost

Indirect cost:
Overhead cost
Down time cost

Maintenance cost = Direct cost + Overhead cost

Maintenance Cost Elements (2/2)

Cost to replace or repair
Losses of output
Delayed shipment Cost
Scrap and rework
Total Maintenance Cost

PM Cost

Down Time Cost
CM Cost
Best level  PM level

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Maintenance Management (1/2)

MM is a powerful systematic methodology to maximize the
facility performance and to improve the maintenance
resource productivity, through optimizing the maintenance
policies for the critical equipment.

MM - is the application of knowledge, tools and scientific

techniques to identifying and analysis the maintenance
activities.

MM - decision-making process to select the best

maintenance policies for improving the equipment
reliability to an acceptable level.

Maintenance Management (2/2)

MM is the art of matching a maintenance's
maintenance s goals
goals, tasks,
tasks and
resources to accomplish a goal as needed.

MM is “do the right things, with the right tools, and in the
right way".
Through:
Define the target and constraints,
I f
Information
ti collecting
ll ti & analysis,
l i
Maintenance planning,
Maintenance organization,
Motivation & direction,
Maintenance control,
Corrective actions, and Learned lessons.

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Maintenance Management History

3rd generation

Higher plant
Availability &reliability
2nd generation Grater safety
Better product quality
No damage to
1st generation Higher plant availability environment
Longer equipment life Longer equipment life
Fix it when it Preventive maintenance
broke

1940 1950 1960 1970 1980 1990 2000

How do you measure MM Success?

Targets

Customer
Satisfaction

Time Cost & Resources

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Maintenance System
A system is a collection of components (or items)
that work together to achieve a certain objective.
- Technical Constraints
‐ Financial constraints

‐Facility / Plan
‐ Target Maintenance 
at acceptable standard
processes
‐ Information
‐ Reports
‐ Resources The output is equipment that 
Maintenance  is up, reliable, and well 
configured to achieve the 
performance 
planned operation of the 
indicators plant.

Functional block diagram for a pump

Sub-system:
y Water Pump
p Unit

Control system

Flow rate: 35 m3/hour

Head: 750 m
Fluid type: Water Pressure: 70 bar

Multi-stage centrifugal
El. Power: 132 kw pump
380 V, 3 ph

Environment

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Main Components

Coupling

Pump
Motor 35 ton/hr
1800 rev/min 60 bar
B1 B2

Main Components Specs

Pump specifications:
- Valves specifications:
- -
-

Motor specifications: Coupling specifications:

- -
- -

Bearing specifications: Strainer specifications:

- -
- -

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Current PM Program
Item Job plan Frequency

(1)
Motor
(2)
Coupling

(3)
Pump

(4)
Suction line
(5)
Discharge line
(6)
Valves

Root Cause Failure Analysis

Item Main Failures Root Cause MTBF

(1)
Motor

(2)
Coupling

(3)
Pump

(4)
Suction line
(5)
Discharge line
(6)
Valves

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As – is – Situation Policies for

the main components
1) Motor
2) Coupling
3) Pump
4) Suction Line
5) Discharge Line
6) Valves
Failure PM PrD CM

Policy Freq. Policy Freq.

Developed PM Plan
Item Job plan Frequency

(1)
Motor
(2)
Coupling

(3)
Pump

(4)
Suction line
(5)
Discharge line
(6)
Valves

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Modern MM Systems
There are four modern approaches:

•Optimal system maintenance (OSM),

•Risk Based Inspection (RBI)

•Reliability centered maintenance (RCM), and

•Total productive maintenance (TPM).

MM Methodologies
OSM RBI & RCM TPM
Main Improve Preserve system Improve
objective equipment function & improve overall system
availability system availability productivity

Approach Maintenance Improve the System overall

information maintenance program analysis
analysis
y and System
y reliability
y Continuous
Using optimal analysis improvement
mathematical Failure mode effect techniques
modeling analysis FMEA
Risk analysis

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Maintenance Policies (1/4)

Maintenance Policies
(1) (5)
Failure-Based Total-Based
Reactive (ReM): Global (GM):
- RTF (3) - OSM
- CM Condition-Based - TPM
- BD Predictive (PdM): ::
:: - Oil analysis
(2)
- Vibration analysis
Time-Based
- Temperature analysis
Preventive (PM): (4)
- Pressure analysis
- Calendar: Risk-Based
- Wear analysis
Weekly Proactive (PaM):
- Efficiency analysis
Monthly - RCFA
::
:: - FMEA \ FMECA
- Running: - HAZOP
1000 R.H. - RCM \ RCM2
1000 K.M. - RBI ::
::

Spectrum Analysis
1xRPM - BALANCE
1.8
1.5 2xRPM - ALIGNMENT
1.2 3-6xRPM - LOOSENESS
0.9
GEARS & ANTI FRICTION BEARINGS
0.6
6-30xRPM 30-50xRPM
0.3

1000 2000 3000 4000

Frequency

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Vibration Spectrum and

Parameter Bands

Sub-
Harmonic 1X 2X Bearing Bearing Gears Bearing
Amplitude

1x 2x 50x
Trend of
Trend of Bearings
Balance
5
mm/sec Alarm
1
Time mm/sec Time
(Days) (Days)

SELECTED FREQUENCY
BAND ALARMING

Sub-
Harmonic 1X 2X Bearing Bearing Gears Bearing
Amplitude

1x 2x 50x
Trend of
Trend of Bearings
Balance
5
mm/sec Alarm
1
Time mm/sec Time
(Days) (Days)

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Maintenance Policies (2/4)

Policy Approach Goals

Run to failure (fix-it when Minimize maintenance costs

Reactive
broke). for non-critical equipment.

Use-based maintenance Minimize equipment

Preventive
program. breakdown.

Maintenance decision Discover hidden failures and

Predictive based on equipment
q p improve
p reliabilityy for
condition. critical equipment.

Detection of sources of Minimize the risk of failures

Proactive
failures. for critical systems.

Maximize the system

Global Integrated approach.
productivity.

Maintenance Policies (3/4)

Policy
y Approach
pp Goals
Identification of root
RCFA Eliminate failures.
causes of failures.
Identification of criticality Improve equipment
FMECA
of failures. availability.

Identification of hazards
HAZOP and problems associated Improve HSE effect.
with operations.

Determination of best
Preserve system function
RCM maintenance requirements
& improve reliability.
for critical systems.

Determination of an
Improve system HSE and
RBI optimum inspection plan
availability.
for critical systems.

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Maintenance Policies (4/4)

Policy Approach Goals

Optimization
Maximize reliability measures
approach for the
OSM and minimize maintenance cost
global maintenance
rates.
system.

Comprehensive
Maximize plant effectiveness and
TPM productive-
resource productivity.
maintenance system.

Maintenance Planning Concept

Before you start to maintenance plan, consider...
•Who is the ultimate customer?
•What are the customer needs?
•How long will the maintenance project last?
•Where are we now?
•Where should we end-up?
•What are the cost constraints?
•What are the technical challenges?
So,, Maintenance Planning g must determines what,, when,, where,,
how, and by whom something is done.
•What is to be maintained? "Description"
•Why? "Target"
•How? "Method"
•By whom? "Resources"
•When? "Schedule“
•Where? "Location"

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Maintenance Planning Steps (1/2)

Step Description
1. System criticality analysis HSE - Process – Down time – Cost – MTBF – MTTR -... etc.
etc

2. Equipment selection • Critical equipment

3. Information collection &
analysis
4. Target & constraints
definitions
5. Requirements & standard
levels
6. Main failures determination
7. Root Cause Failure Analysis
(RCFA)
8. Best maintenance policy
• Non-critical equipment
Maintenance catalog – Design information – Equipment history-
Working conditions- PMs – CMs – Trouble shooting – Reliability
information – HSE instructions. etc.
• Targets: Reliability, Availability, MTBF, MTTR, Down time,
Cost, HSE level, .. etc.
• Constraints: Budget, Spare parts, Tools, Manpower,
Information,etc.
• Functional levels: Flow rate, Head, Pressure, Power, .. etc.
• HSE levels
Functional failures - HSE failures – Mechanical failures –
Electrical failures - .. etc.
Main failures, Root cause, RRC, Mechanism, Probability, MTBF,
MTTR, Remedy.
• Run To Failure (RTF)
• Time-based (Preventive) PM
• Condition-based (Predictive) PdM
• Risk-based (Proactive) PrM

Maintenance Planning Steps (2/2)

Step Description
9. Maintenance policy planning Frequency- Levels- Alarm limits- Tools- Job plan- HSE plan- Spare parts-
Duration- Manpower- .. etc.
10. Work orders • W/O # - W/O type- Dates/time - Responsibility- Level - Alarm limits-
Tools- Job plan- HSE plan- Spare parts- Duration- Manpower- Failure -
Root cause- .. etc.
• Complete Feedback.
11. Measure Running hours- Noise- Vibration- Temperature- Oil level- viscosity- Flow
rate – Head – Speed - .. etc.
12. Analysis Noise analysis- Vibration analysis – Temperature analysis - Oil analysis -
Flow rate analysis – Head analysis – Speed analysis - .. etc.
13 Action
13. A ti - Good
G d condition
diti
- Call for service (PM)
- Call for repair (planned CM)
- Breakdown (unplanned CM)
14. Performance evaluation & CM/PM- MTBF- MTTR- MTBM- MTTM- Reliability – Availability-
KPI Maintainability- RAM- Spare parts consumption rates- .. etc.
15. Improvement • Information – Maintenance levels- Tools – Spare parts – Manpower
skills – Time – HSE - .. etc.
• Approach: FMEA - RCM - RBI- PMIS - .. etc.

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The Main Elements of

Maintenance Plan
Equipment name & code,
Eq ipment priority,
Equipment p io it
Maintenance start time,
Maintenance down time,
Maintenance level and type,
Maintenance job description,
Maintenance operations time,
Maintenance effort (man-hour),
Manpower requirements planning,
planning
Spare parts and supplies requirement planning,
Tools requirements planning,
Failure analysis,
Maintenance cost estimation,
Maintenance budget, and
Safety instructions.

Maintenance Work Order

•Work order number
Requester Section:
•Plant (or department) name / code, Equipment name / code
•Equipment priority, Maintenance type & level (PM / Repair / Overhaul)
•Job scope & description, Responsibility
Planning Section:
•Manpower types & skills, Time estimation
•Spare parts, Special tools
•Expected equipment down time (from xxx to xxx), Cost estimation
•Safety
y instructions,, Responsibility
p y
Craft Feedback:
•Job scope & description, Manpower types & skills
•Time estimation, Spare parts
•Special tools, Actual equipment down time (from xxx to xxx)
•Actual Cost, Responsibility
Coding:
•Plant (or department), Equipment
•Resources (Manpower, Spare parts, Special tools)

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Maintenance Control
Total Control Indicators:

1- Work quantity control

Over estimation, Under estimation

2- Time control
Behind schedule (late), Ahead schedule (early)

3- Cost control
Cost overrun, Cost under-run

4- Quality control
A
Acceptable
t bl level,
l l Non-acceptable
N t bl level
l l

5- Inventory control
Over estimation, Under estimation

6- Resources control
Over estimation, Under estimation

7- Plant condition control (HSE, etc.)

Acceptable level, Non-acceptable level

Control Steps
1.
1 Whatt to
Wh t control?
t l?
2. What is the standard (target) performance?
3. What is the actual performance level?
4. Comparison between the actual & target.
5. Detection of variance
6
6. Identification of causes of variance
7. Corrective actions
8. Learned lessons.

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Total Control Levels

1-
1 Review and data collection.
collection
2- Follow-up.
3- Performance evaluation.
4- Productivity analysis.
5- Corrective actions.
6-
6 Learned lessons.

System Effectivness
System Effectiveness

Efficiency Availability

Utilization & R li bili
Reliability M i i bili
Maintainability

Resource productivity MTBF MTTR

MTBM MTTM

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Resources Productivity Analysis

Productivity Dimensions
Time Quantity Quality Cost
Effectiveness Efficiency
= Actual output / 1- Technical Efficiency
Planned output 2- Operating Efficiency
3- Production Efficiency
4- Economical Efficiency
Maintenance System Effectiveness:
•It is related to performance
performance.
•It is the degree of accomplishment of objectives.
•How well a set of results is accomplished?

Maintenance System Efficiency:

•It is related to resource utilization.
•It is the degree resources utilization.
• How well the resources are utilized to achieve the results.

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