Maintenance for

Repairable and Non-repairable Item

(Replacement Policy)

Maintenance and Reliability Engineering (TI 141316)

IE Department
Institut Teknologi Sepuluh Nopember (ITS)
REPAIRABLE ITEM
 Repairable Items
One which after failing to function properly
may be restored to satisfactory working order
by replacing or repairing certain components
(Wolstenholme, 1999)
An item which can be restored to perform all
of its required functions by corrective
maintenance (MIL-STD-721C).
 Types of repair
Minimal repair (failure
rate after repair is same
as rate before failure)
Imperfect repair (failure
rate after repair better
or worst than rate
before failure)
Perfect repair (as good
as new, failure rate after
repair same as failure
rate of new items)
Mean Time
(MIL-STD-721C)

MEAN TIME BETWEEN FAILURE (MTBF): A basic measure of

reliability for repairable items: The mean number of life units during
which all parts of the item perform within their specified limits,
during a particular measurement interval under stated conditions.
MEAN TIME TO FAILURE (MTTF): A basic measure of reliability for
non-repairable items: The total number of life units of an item
divided by the total number of failures within that population, during
a particular measurement interval under stated conditions.
MEAN TIME TO REPAIR (MTTR): A basic measure of maintainability:
The sum of corrective maintenance times at any specific level of
repair, divided by the total number of failures within an item repaired
at that level, during a particular interval under stated conditions.
 MTBF vs MTTF
The main difference between the MTBF (mean
operating time between failures) and the
MTTF is in usage.
MTTF may apply to first failure or a non-
repairable failure, whereas MTBF is used in
the context of repairable items.
So concern more on MTBF
Whereas, MTTR much smaller than MTTF
 Aspect of interest
Occurrence of failure / number of failure
Time of failure may be plotted against time to reveal
patterns and unusual features of data
Cost of failure
Repair/maintenance time (assumed: smaller
than in-service time)
Supposed Xi is time between the (i-1)th and
ith failures (consider as operating time if the
down times are negligible)
 Modeling of repairable items
1. The number of failures over span of time
2. The nature of operating time Xi may
constitute long term trend detection and
estimation of trend is a major of interest
3. Availability of items

Importance of modeling: will affects the necessary

human resources, spare part provisioning, cost of
repair, and operational effectiveness
 Modeling number of repair
MCRF (mean cumulative repair function)
plots of the cumulative number of failures
against time (for only one item)
Often reveal simple power law that describe
the evolution of the measures with time.
Let N(t) = number of failure in time interval
(0,t), then
MCRF E[ N (t )]
 Modeling number of repair

Applying a power law: E[ N (t )] At
Take log for both side:

log MCRF log( At ) log A log t
Plot of log MCRF against log t known as Duane Plot .
Estimate of as the slope of the fitted line.
The Rate of Occurrence of Failure (ROCOF) or
intensity function, is defined as:
d d
(t ) E[ N (t )] ( At ) A t 1
dt dt
 Modeling number of failure
Estimation of (slope of linear regression
equation will refer to ROCOF)
If 01, the ROCOF decreases (happy system)
If =1, the ROCOF is constant
If 1, the ROCOF increases (sad system)
 Example 1 (one item)
The following data concern repairs to a large
number of motor vehicles (945 units) in a
warranty period. The Months in Service (MIS)
and cumulative repairs per unit have been
arranged over the 945 vehicles.
MIS 1 2 3 4 5 6 7 8

MCRF 0.397 0.547 0.688 0.807 0.95 1.064 1.173 1.305

 Example 1 MIS MCRF log MIS log MCRF
SUMMARY OUTPUT 1 0.397 0 -0.40121
2 0.547 0.30103 -0.26201
Regression Statistics
3 0.688 0.47712125 -0.16241
Multiple R 0.996563
R Square 0.993138 4 0.807 0.60205999 -0.09313
Adjusted R 5 0.95 0.69897 -0.02228
Square 0.991994 6 1.064 0.77815125 0.026942
Standard Error 0.015775
Observations 8 7 1.173 0.84509804 0.069298
8 1.305 0.90308999 0.115611
ANOVA
Significance
df SS MS F F
Regression 1 0.216103 0.216103 868.3976 1.01E-07 0.2
Residual 6 0.001493 0.000249
Total 7 0.217596 0.1

0
Coefficient Standard 0 0.2 0.4 0.6 0.8 1

log MCRF
s Error t Stat P-value -0.1
Intercept -0.42227 0.012544 -33.6618 4.58E-08
-0.2
X Variable 1 0.575172 0.019518 29.46859 1.01E-07
-0.3
slope = 0.57, then refers to decreasing -0.4
failure rate
-0.5
Log MIS
 Example 2 (several items)
Nelson (1988) consider repair for six repairable items, all commissioned at
time zero but each subject to retirement over time. The data cover 42
months, where indicated repair (x), retirement (o).
 Example 2
event time (months) mean repair cumulative mean repair (MCRF) log t log MCRF
1 repair 2 1/6 0.166667 0.166666667 0.30103 -0.77815
2 repair 5 1/6 0.166667 0.333333333 0.69897 -0.47712
3 repair 8 1/6 0.166667 0.5 0.90309 -0.30103
4 repair 8 1/6 0.166667 0.666666667 0.90309 -0.17609
5 repair 12 1/6 0.166667 0.833333333 1.079181 -0.07918
6 retaired 12 0.833333333 1.079181 -0.07918
7 repair 14 1/5 0.2 1.033333333 1.146128 0.01424
8 retaired 16 1.033333333 1.20412 0.01424
9 repair 17 1/4 0.25 1.283333333 1.230449 0.108339
10 repair 18 1/4 0.25 1.533333333 1.255273 0.185637
11 repair 19 1/4 0.25 1.783333333 1.278754 0.251233
12 retaired 20 1.783333333 1.30103 0.251233
13 repair 26 1/3 0.333333 2.116666667 1.414973 0.325652
14 retaired 29 2.116666667 1.462398 0.325652
15 retaired 33 2.116666667 1.518514 0.325652
16 repair 39 1/1 1 3.116666667 1.591065 0.49369
17 retaired 42 3.116666667 1.623249 0.49369
 Example 2

Regression Analysis: log MCRF versus log t

The regression equation is

log MCRF = - 1.13 + 1.02 log t

Predictor Coef SE Coef T P

Constant -1.12799 0.04735 -23.82 0.000
log t 1.02287 0.04132 24.75 0.000

S = 0.0462537 R-Sq = 98.7% R-Sq(adj) = 98.6%

slope = 1.02, then repair rate is fairly

Analysis of Variance
constant
Source DF SS MS F P
Regression 1 1.3109 1.3109 612.74 0.000
Residual Error 8 0.0171 0.0021
Total 9 1.3280
 Availability
Items / system, throughout its lifetime, will
undergo alternating between in-service times
and repair/maintenance times
MTTF
A()
MTTF MTTR
Availability
 Estimate the availability
Constant repair rates
Assumed time to repair is constant repair rate, thus
PDF and MTTF
1
v (t ) v m(t ) ve vt
MTTR
v
A(t) is availability and A(t ) is un availability
t is the conditional prob of failure during t, given
that the system is available at t
t is the conditional prob that items is repaired
during t, given that the system is un available at t
Then,
Availability 1

 Example 3
Times (in days) over a 6-months period (182.5 days) at which
failure of a production line occurred (Tf) and times (Tn) at
which the plant was brought back on line following repair.
i Tf Tn
1 12.8 13
2 14.2 14.8
3 25.4 25.8
4 31.4 33.3
5 35.3 35.6
6 56.4 57.3
7 62.7 62.8
8 131.2 134.9
9 146.7 150
10 177 177.1
 Example 3
i Tf Tn Tf(i) - Tf(i-1) Tf(i) - Tn(i-1) Tn - Tf
1 12.8 13 12.8 12.8 0.2
2 14.2 14.8 1.4 1.2 0.6
3 25.4 25.8 11.2 10.6 0.4
4 31.4 33.3 6 5.6 1.9
5 35.3 35.6 3.9 2 0.3
6 56.4 57.3 21.1 20.8 0.9
7 62.7 62.8 6.3 5.4 0.1
8 131.2 134.9 68.5 68.4 3.7
9 146.7 150 15.5 11.8 3.3
10 177 177.1 30.3 27 0.1
sum 177 165.6 11.5
 Example 3
1 10 1
A(T ) n f 182.5 (0.2 0.6 0.4 1.9 0.3 0.9 0.1 3.7 3.3 0.1) 0.063
T i 1
(T T )

A(T ) 1 0.063 0.937

1

10
MTTF i 1
(T f Tn 1 )
N
1 165.6
(12.8 1.2 10.6 5.6 2.0 20.8 5.4 68.4 11.8 27.0) 16.56
10 10
1 10
MTTR i 1 (Tn T f )
N
1 11.5
(0.2 0.6 0.4 1.9 0.3 0.9 0.1 3.7 3.3 0.1) 1.15
10 10
1 1
A(T ) 0.935
1
MTTR
1
0.85
MTTF 16.5
 Estimate the availability
Steady state availability is also given by
MTBF 1 n

MTBF MTTR 1 n 1 n
(for a series system of n units each with
exponential lifetime, parameter , and repair
time distribution exponential with rate )
NON REPAIRABLE ITEMS
 Replacement
For non repairable item, the failure will result the replacement
activities
For system subject to wear (IFR), the PM can be substantially
increase reliability.
Although the capital cost of equipment may be increased, it will no
longer be necessary to replace parts at fixed intervals, some of
which may be capable of much longer operation wear monitoring
is essential
However, many situations in which failures caused by aging cannot
be anticipated through monitoring how often parts should be
replaced
Major classification of replacement models:
Age replacement
Block replacement
 Age replacement
Parts is replaced after it has been in operation
for time T.
If a part fails at time tf, it is replaced and the
next replacement does not take place until tf +
T or at the time of the next failure, whichever
comes first.
Operational cost of parts over a span of time:
C = Nf C f + N p C p
 Age replacement
Where:
Nf = expected number of failures
Np = the number of replacements of unfailed
parts during t
Cf = cost of part failure and consequent
replacement
Cp = cost of replacing the unfailed part during PM
N = Nf + Np
Supposed that total time is very long compared
to the MTBRepl, then N = t / MTBRepl
 Calculating MTBRepl
R(t) = prob that a part will operate for a time
greater than t without replacement.

R(t) = R(t) at tT, then MTBRepl 0 R (t ) 0 R(t )dt
T
'

t tR(T ) t[1 R(T )]

N T N p R(T ) N N f [1 R(T )]N T

T

0
R(t )dt 0
R(t )dt 0
R(t )dt

t[1 R(T )] tR(T )

C (T ) T
Cf T
Cp
0
R(t )dt
0
R(t )dt
 Replacement interval T
Choose an age replacement interval T that will
minimize the cost
T Cp
R(T ) (T ) R(t )dt 1
0 C f Cp

For 2 parameter Weibull distributions, then

1m
1 Cp
T
m 1 C f
 Block / Batch replacement
Item is replaced at time T, 2T, 3T, and whenever
a failure occurs
There is no need to keep track the time of the
preceding replacement. For maintaining large
number of relatively inexpensive parts.
Example: bulbs in a large number of street lights
are more likely to be replaced in batches.
However, turbine blades on a large
turbogenerator will be replaced when they have
acquired a specified age.
 Block / Batch replacement
Generally, batch replacement will remove
more unfailed item than age replacement.
After a part has failed and been replaced, the
new part will iteself be removed at the next
batch replacement, before it has acquired an
age T
Conversely, there will be fewer failures with
natch replacement, since some of parts will be
replace before T
 Block / Batch replacement
Np = t/T and Nf = N(T)/T
N(T) is expected number of failure between
batch replacement
Since for block replacement, Nf will be smaller
and Np larger than for age replacement, the
optimum for Cf>Cp will occur for somewhat
larger value of T
 Bibliography
Lewis, E.E., (1987), Introduction to Reliability
Engineering, 2nd ed, John Wiley & Sons, Canada.
Wolstenholme, L., (1999), Reliability Modelling, a
Statistical Approach, 1st ed, Chapman & Hall/CRC,
Florida.
Jardine, A.K.S., (1973), Maintenance,
Replacement, and Reliability, 1st ed, Pitman
Publishing, NY
Department of Defense, (1981), MIL-STD-721C:
Definitions of terms of reliability and
maintainability, Washington DC