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MSc Maintenance Management

MMH131155
Reliability and Availability Assessment
Senior Lecturer: Dr Babakalli Alkali
2014
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Module Leadrer
TITL NAME
E
Dr
Babakalli Alkali
Room:
Phone:
Email:

C013
0141 331 3576
babakalli.alkali@gcal.ac.uk

B.M Alkali
(BSc, MSc, PhD, MORS, MIMA, FHEA)
Senior Lecturer in the Department Engineering
School of Engineering and Built Environment, Glasgow Caledonian University,
Cowcaddens Road, Glasgow G4 0BA
Phone: +44-141 331 3576, Fax: +44-141 331 3690
E-mail: babakalli.alkali@gcu.ac.uk
Dr Babakalli is the AHoD of Department of Mechanical Engineering, and the module leader for maintenance
management, reliability and availability and TOGI module at Glasgow Caledonian University. Tutor for the Energy
Audit and Energy Asset Management module.
Dr Babakalli was a Research Fellow at Strathclyde University, Department of management science, Strathclyde
Business School, Glasgow (2005 - 2008).
He holds a BSc in Statistics and an MSc and PhD in Operational Research and Applied Mathematical Statistics from
the Centre of Operational Research and Applied Statistics, University of Salford, Greater Manchester.
His PhD research work is in industrial risk, reliability and maintenance modelling of complex systems (oil platform gas
turbines and gas generators). His research focus is on industrial and energy assets. He is active in data acquisition and
gathering, performs analysis and relative comparison to support effective decision making process.

Research Interest
1.Energy asset management
2.Renewable energy
3.Reliability Management
4.Applied probability modelling
5.Stochastic processes
6.Maintenance Optimization
7.Risks and availability assessment

PhD Students (3)


1.3 Completions
2.P/T PhD: Modelling of the failure process for cost effective maintenance scheduling of MV
XLPE cables with consideration of operating temperature and earth leakage

Postgraduate Supervision (43)


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Companies and organisation in


which collaborations has been
established

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Module Summary
This module aims to provide an understanding of the
fundamentals of reliability and decision theory. It will
examine these techniques as applied to risk, reliability,
availability and maintenance management. It will also
bridge the gap between theoretical subject of "Reliability
Engineering" (RE) and day-to-day equipment maintenance
practice. In addition, techniques will be treated to analyse
field data to report on business targets. Apart from these
quantitative approaches, attention will be paid to a variety
of formal, qualitative risk identification and maintenance
optimisation methods used in industry.
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On completion of this module, you


should be able to

Use the concepts of probability and stochastic decisions theory to


quantitatively analyse a (production) system w.r.t. the risks of not meeting
safety and/or environmental targets.
Quantitative assessment of production capacity (probability, reliability and
maintenance characteristics.
Using this theoretical insight and engineering views, employ techniques to
quantify the effects of various maintenance and inspection strategies,
manpower and activity planning/scheduling strategies for spare parts logistics.
Use field data to analyse the impact of implemented maintenance strategies on
the company business plan.
Understand the strength and limitations of quantitative RMA techniques and
compare these with qualitative/normative methods used in industry.
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Teaching Mode
Lectures
Tutorials
Case Studies

Assessment Briefs
Assessment Method
Coursework 50%
Exams 50%
START
WEEK
4

END
WEEK
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TYPE

DESCRIPTION

Coursework Reliability Analysis CW1 (25%),


Risk Analysis CW2 (25%)
Exams
Answer Any 3 out of 6 Questions

HOURS

WEIGHING

16

50%

2 hours

50%

Please note the following statement on plagiarism:- 'The deliberate and


substantial unacknowledged incorporation in your submission of material
derived from work (published or unpublished) of another is prohibited. In
such cases the work submitted is classified as illegal and will result in
further action being taken by the University which may include recording a
failure.'
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Indicative Reading list

Practical Reliability Engineering, 4th Edition, P O'Connor, Wiley (2006)

Maintenance, Replacement and Reliability: Theory and Applications, AKS Jardine


and AHC Tsang (2006)

Reliability and Risk Assessment, JD Andrews and TR Moss, Professional Engineering


Publishing (2002)

Case Studies in Reliability and Maintenance., WR Blischke and DNP Murthy (2003)

Reliability Data Handbook, TR Moss, (2004)

QUESTIONS?

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Background
The recognition of reliability and maintainability as
vital factors in the development, production, and
maintenance of todays complex systems has placed
greater emphasis on the application of design evaluation
techniques to logistic management. Reliability and
maintainability can identify critical failure modes and
causes of failure and provide an effective tool for
predicting equipment behaviour and selecting
appropriate measures to ensure satisfactory
performance
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Introduction
Reliability has always been an important aspect in the
assessment of industrial products and/or equipments.
Good product design is of course essential for products with
high reliability. However, no matter how good the product
design is, products deteriorate over time since they are
operating under certain stress or load in the real environment,
often involving randomness. Maintenance has, thus, been
introduced as an efficient way to assure a satisfactory level
of reliability during the useful life of a physical asset.
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Reliability Engineering

The study of reliability engineering is based


on the improvement, analysis, assessment
and prediction of performance of equipment
and systems

Many reliability analysis require the use of


statistical techniques to aid in the analysis
and prediction of performance of systems
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History of Reliability

The notion of quantitative analysis of reliability is


dated back to the 1940s

The need for modern technology in the space program


led to quantitative approach based on mathematical
modelling and analysis

This gave impetus to the rapid development of


reliability theory and methodologies in the 1950s
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Reliability History

A more quantitative approach to reliability grew in demand and


particularly out of the experiences in the II World War with complex
systems [Barlow and Proschan (1965)].

Barlow (1984) provide a historical perspective of mathematical


reliability engineering in electronic equipment in space reliability
technology

The 50th Anniversary Special Publication of the IEEE Transaction on


Reliability (Vol 47, No 3-SP Sept. 1998) contains several historical
papers dealing with various aspects of reliability applications
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Current Reliability Prediction

Reliability predictions is performed in the early stage


of a development programme (design stage)

The awareness of potential degradation of equipment


during life cycle

The performance of reliability prediction for electronic


systems is well established by R&D, for example MILHDBK-217
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Reliability Prediction Methods

Reliability prediction is based on databank information and a


wide dispersion of failure rates which occur for similar
components

Standardisation and the mass production of electronic parts


has permitted the creation of valid failure rates for high
population electronic devices

Quality information can be used directly to predict operational


reliability while design is still on the drawing board
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Inconsistencies in failure rates


(mechanical equipment)

Individual mechanical components such as valves and gearbox


perform more than one function and failure data for specific
applications of nonstandard component are seldom available
Failure rates of mechanical component are not described by
constant failure rate because of fatigue, degradation and other
stress-related failure mechanism
Mechanical equipment reliability is more sensitive to loading,
operating condition than electronic equipment
The definition of failure of mechanical equipment depends
upon its application (e.g excess noise or leakage)

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Why are definition important?


Definitions and standards in reliability engineering are of great significance due to
the following reasons:

They are written by authorities in the field; practitioners, and academics who are
gurus in the field.
They are therefore written very carefully so that it is difficult to swap any word in
the definition with an alternative one.
They stand time. Definitions last for generations.
They influence cultures. For example failure in the West is defined as termination
of function, whereas the Japanese treat it as deterioration of function and hence
the six losses. This has influenced our design of CMMS in capturing failure.
They help to standardise the language (for example for contracts and for recording
failures).
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What is Reliability?

One of the quality characteristics that


consumers require from the manufacturer
of products is reliability.
But what is reliability?
The ability for an equipment to performs its
function when required (e.g starting your car).
Importance of reliability:
Examples of failure and success cases.
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Reliability

The reliability of an item in use generally deteriorate with age.


This deterioration could be affected by several factors
including environment, operating conditions and maintenance

Deterioration can be slowed by increasing maintenance but at


increasing costs

Note that the reliability of a product varies over it lifecycle,


and a thorough reliability analysis may be necessary at many
stages
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Definition of Reliability
Reliability is the probability that a product or service will
operate properly for a specified period of time (design life)
under the design operating conditions (such as temperature
or volt) without failure. (Elsayed, 1996)
In other words, reliability may be defined as a measure of
the systems success in providing its function properly.

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Selected Definition

Reliability: ..
Redundancy: ..
Failure: ..
Maintainability:
Availability:..

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Selected Definition

Reliability: The ability of an item to perform a required function under stated


conditions for a stated period of time (BS 4778).
Redundancy: The existence of more than one means of accomplishing a given
function. Each means of accomplishing the function need not necessarily be identical
(MIL-STD-721B).
Failure: The termination of the ability of an item to perform a required function (BS
4778).
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 functions, when
maintenance is performed under stated conditions and using prescribed procedures and
resources (BS 4778).
Availability: The ability of an item (under combined aspects of its reliability,
maintainability and maintenance support) to perform its required function at a stated
instant of time or over a stated period of time (BS 4778).
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Maintenance Terminology

Item related terms


Properties of items
Failures and events
Faults and states
Maintenance types and strategies
Maintenance activities
Time related terms
Maintenance support and tools
Economical and technical indicators

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Maintenance Terminology
Basic terms

Maintenance
Improvement
Modification
Failure
Fault
Availability
Reliability
Maintainability
Supportability

Preventive Maintenance
Corrective Maintenance
Predetermined Maintenance
Condition Based Maintenance
Immediate Corrective Maintenance
Deferred Corrective Maintenance
Cost Efficiency
Productivity
Asset Management
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Maintenance Terminology

Maintenance

Combination of all technical, administrative and managerial


actions during the lifecycle of an item intended to retain in it,
or restore it to a state it can perform the required function

Improvement

Combination of all technical, administrative and managerial


actions intended to ameliorate the dependency of an item,
without changing its required function

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Maintenance Terminology

Modification

Combination of all technical, administrative and managerial


actions intended to change the function of an item
Note: modification does not mean replacement by an equivalent
item
Note: Modifications is not a maintenance action but has to do with
changing the required function of an item to a new function. The
changes may have an influence on the dependability or the
performance of item or both
Note: Modification may be allocated to the maintenance
organisation
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Maintenance Terminology

Failure

Termination of the ability of an item to perform a required function


Note 1: After a failure the item has a fault which may be complete or
partial.
Note 2: Failure is an event as distinguished from faults which is
a state.

Fault

State of an item characterised by inability to perform a required


function, extending the inability during preventive maintenance or
other planned actions, or due to lack of external resources
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Summary: The Definition of


Reliability
Reliability determines to what degree a system/systems
are able to achieve the intended function/performance
in spite of errors, disturbances and limited maintenance
resources
The variable used
for measuring
reliability is
availability

A=100%

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Availability

Availability depends on reliability and maintainability

To predict systems availability, both failure and repair


probability distribution must be considered. We with the
general observation the
Availability

Uptime
Uptime Downtime

Total uptime and downtime will provide the percentage


time the system is available. The main interest is to predict
the availability
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Relationship between the CONCEPTS


of RELIABILITY

Influence the technical


system the machine or
plant

Influence the maintenance


system

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Maintenance Terminology
Availability
Performance

Reliability

Maintainability

The technical system

Maintenance
Supportability
The maintenance system
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Relationship between the CONCEPTS


of RELIABILITY
Availability time for production
Mean
Downtime

Mean time bt. failure

MTBF

Mean
Waiting
Time

MWT

Mean
Time To
Repair

MTTR

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Relationship between the CONCEPTS


of RELIABILITY
The item is
available for use

Simple and fast


Maintenance
activity

The right resources


at the right place
at the right time

Seldom
a down state
of the item

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What has the biggest


influence upon the result?

Major

Design

70%

70%

10%

Moderate

Production

20%

10%

20%

Minor

Maintenance

10%

20%

70%

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Relationship between the CONCEPTS


of RELIABILITY
MTBF
Varies due to:
# Condition
monitoring.
# The design.
# Redundancy.
# Choice of
equipment or
components.

MWT
Varies due to:
# Organisation.
# The information
systems.
# Routines.
# Education.
# Training.

MTTR
Varies due to:
# Accessibility.
# Built in test.
# Fault indication.
# Staffs
knowledge.
# Staffs
motivation
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Maintenance Terminology

Availability performance

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
Note 1: This ability depends on the combined aspects of the reliability, the
maintainability and the maintenance supportability
Note 2: Required external resources, other than maintenance resources do not
affect the availability of item

Reliability

The ability of an item to perform its required function under a given condition for a
given period of time
Note: The term reliability is also used as a measure of reliability performance and
may also be defined as probability
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Maintenance Terminology

Maintainability

Ability of an item under a given condition of use, to be restored to a state in which


it can perform a required function, when maintenance is performed under given
conditions and using stated procedures and resources

Note: the term maintainability is also used as a measure of maintainability


performance

Maintenance Supportability

Ability of a maintenance organisation of having the right maintenance support at


the necessary place to perform the required maintenance activity at a given instant
of time or during a given interval

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Maintenance Terminology
MTTF

MTW

Up state

MTTR

Down state

Total time interval

Aa=MTTM/(MTTM+MTW+MTTR)
Aa= Achieved availability
MTW= Mean Time Waiting

MTTF=Mean Time to Failure


MTTR=Mean Time to Repair

Note: This formula is only taking into account faults and corrective maintenance
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Maintenance Terminology
MTTM

MTW

Up state

Down state

Total time interval

Ao=MTTM/(MTTM+MTW+M)
Ao= Operational availability
MTW=Mean Time Waiting
MTTM: Mean Time to Maintenance Time (preventive and corrective)
M=Mean Maintenance Time (Time to preventive and corrective maintenance)
Note: In this calculation of Ao, only maintenance actions which cause stoppage
Time for the operational use of the technical system will be considered

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Maintenance Terminology
Maintenance

Preventive Maintenance

Corrective Maintenance

Condition based
maintenance

Predetermined
maintenance

Scheduled,
continuous or on
request

Scheduled

Deferred

Immediate

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Maintenance Terminology
Preventive Maintenance (PM)
Maintenance carried out at predetermined intervals or according to prescribed criteria and
intended to reduce the probability of failure or the degradation of the functioning of an item.

Condition Based Maintenance (CBM)


Preventive maintenance based upon performance and/or
parameter monitoring and the subsequent actions.
NOTE: Performance and parameter monitoring may be scheduled, on request or continuous.

Predetermined Maintenance (PDM)


Preventive maintenance carried out in accordance with
established intervals of time or number of units of use but without previous condition
investigation.

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Maintenance Terminology
Corrective Maintenance (CM)
Maintenance carried out after fault recognition and intended to put an item into a state
in which it can perform a required
function.

Deferred Maintenance (DM)


Corrective maintenance which is not immediately carried out
after a fault detection but is delayed in accordance with given
maintenance rules.

Immediate Maintenance (IM)


Maintenance which is carried out without delay after a fault has been detected to avoid
unacceptable consequences.
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Maintenance Terminology
Cost
Direct cost
Indirect cost
External cost

Cost efficiency
RESULTS/COSTS

Activities

Results

Effect

Preventive Maint
Corrective Maint
Reinvestment

Few functional dist


Few failure
The state of the
assets

AVAILABILITY
MIN DISTURBANCES
QUALITY

Resources

Productivity

Direct hours
Indirect hours
Use of technical
resources

RESULTS/USED
RESOURCES

Maintenance
Decision: Cost
Effective Strategy

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Maintenance Terminology
Company management designers
Project managers

Right
Capacity

Production
Management

Maintenance
Management

Right
Production

Right
Maintenance

Right
Logistics

Logistics management

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Maintenance Terminology
For further information about Maintenance
terminology
See the European Standard
CEN EN 13306, Maintenance Terminology

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Actions to improve reliability from


design state

Factors of safety.
Leads to the compounding of many different safety factors.
Compensate for uncertainty.
Lead to over design(increased weight and cost).
Redundancy.
Compensate for uncertainty.
Lead to over design(increased weight and cost).
Extensive testing.
Significant increase in expenditure.
Can lead to product launch delays.
Test environment may be an inadequate simulation of the operating
environment.
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Conventional reliability prediction


requires databut
A substantial number of failures need to have already
occurred for the system to be assessed.
There is a need for reliability data at parts level, of which
there appears too little.
Existing data sources are often not relevant to new
product designs because of the evolution in materials and
manufacturing technology.
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To cope with such difficulties there


is need to rely on
Probability theory so that one can model
and predict failure or optimal time to carry
out PM actions
Perform relative comparison in terms of
performance so that one need not rely on the
availability of large number of failure data.
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Thank you any questions?

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