MAE 465

Maintenance Engineering
Introduction and Definitions
Book 1: Chapter 1
Book 2: Chapter 1
Assistant Professor Altay Zhakatayev
Spring 2024
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Failures
• Failure – the termination of the ability of an engineered object to
carry out its intended function for which it was designed and built.
• A failure is an event that occurs at a specific moment in time.
• Operational state – functional condition of an object.
• Failed state or fault – dysfunctional condition of an object.
• Error – discrepancy between ideal (expected) and real (observed)
value.
Operational state Failure

Failed state
time
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Failures
• Failures are unpredictable. Failures depend on design, manufacture,
maintenance, operation, and human factor.
• Failures can be classified according to their causes, effects, and
detectability.
• Random failure – due to degradation or unexpected external input.
• Systematic failure – due to bad design.
• Consequences of failure vary from
inconvenience to fatal and catastrophic.
• Failures are bad!

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[1] https://www.powermag.com/investigating-the-sayano-shushenskaya-hydro-power-plant-disaster/ Sayano-Shushenskaya Hydro Power Plant Disaster, 2009 [1]
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Why Maintenance Engineering?

• Every tool or equipment is unreliable in the long term.
 They degrade with time and usage
 Eventually, they fail
• Maintenance Engineering addresses the failure problem.
• Maintenance Engineering prevents failures and minimizes their
impact.
• Maintenance Engineering focuses on random failures. Random
failures are unpredictable, systematic failures are predictable.

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What is Maintenance?
• What is maintenance?
 Keep things running
 The work needed to keep something in good condition [Cambridge
Dictionary]
 The upkeep of property or equipment [Merriam-Webster]
• What is engineering?
 The application of science to solve practical problems Science
 The branch of science and technology concerned
with the design, building, and use of engines, Engineering
machines, and structures

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What is Maintenance Engineering?

• What is maintenance engineering?
 Scientific method of maintaining equipment in its working condition
 The discipline and profession of applying engineering concepts for the
optimization of equipment, procedures, and departmental budgets to achieve
better maintainability, reliability, and availability of equipment [Wikipedia]
 Maintenance is the combination of all technical, administrative, and
managerial actions during the life cycle of an item intended to retain it in, or
restore it to, a state in which it may perform the required function [CEN,
2001].
 Maintenance Engineering designs tasks and activities that minimize the risk of
failure.

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Goals of the Maintenance Engineering

• Keep things running and working safely as long as possible and with as low
budget and effort as possible. Ensure that things do not fail.
• Increase reliability
• Improve maintenance operations and organizations
• Reduce the amount and frequency of maintenance (maintenance is costly,
but failure is more costly)
• Simplify maintenance procedures
• Reduce maintenance skills required
• Plan the care of high-value assets for availability and performance
• Assess the regular and sudden failures in machines

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Importance of Maintenance Engineering

• Each year $300 billion (1970s) and $800 billion (1990s) is spent on plant
maintenance by US industry, and 80% of that is spent on the correction of
failures, one third is wasted due to inefficient management.
• The annual cost of maintaining a military aircraft in the US is around $1.6
million, which is roughly five McLaren 720S cars.
• F-16 Fighting Falcon requires on average 16 hours of maintenance for every
hour of flight.
• One day of large manufacturing plant being out of action costs $1-2m
• Maintenance costs 20-50% of all operating costs in mining industry
• Due to bad storage conditions, equipment worth $1.8b was damaged in
the USA (Abrams, Bradley, and Stryker parts) in 2023.

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Importance of Maintenance Engineering

• One day of A340 or Boeing 747 being out of action costs $500k.
• One airplane crash on average costs $500m.
• Maintenance costs 15-20% of all
operating costs in airplane industry
• Maintenance cost $1340 per flight hour
for average airplane
global airplane maintenance cost forecast (2020-2030)

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https://www.keystonelaw.com/keynotes/how-is-compensation-calculated-after-an-aviation-accident
https://www.iata.org/contentassets/bf8ca67c8bcd4358b3d004b0d6d0916f/fy2021-mctg-report_public.pdf
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Importance of Maintenance Engineering

• Around 10-15% of all fatal accidents are related to maintenance
operations or their lack [EU OSHA].
• In October 2023 due to explosion of the methane gaseous mixture
(coal mine methane) 46 people died in Kostenko coal mining,
Karaganda. Probable main cause: inadequate ventilation.
• In 1988 Piper Alpha oil platform disaster killed 165 men in UK. Main
cause is inadequate maintenance procedure.

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[1] https://www.onlinesafetytrainer.com/piper-alpha-oil-platform-disaster-of-1988/ Piper Alpha oil platform [1]
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Types of Maintenance
• Preventive (proactive) Maintenance – before failure
 Observe and adjust
 Future of maintenance management Preventive M Failure
 Requires data collection
 Equipment-driven Corrective M
• Corrective (reactive) Maintenance – after failure time
 “Don’t fix it if it isn’t broke”
 Initial stage of the development of maintenance science
 The most expensive maintenance strategy. Requires extensive spare parts inventory
for any possible failure, as well as all-time personnel readiness
 Doesn’t require data collection
 Event-driven
• CM is on average three times more costly than PM
What examples can you give for PM and CM?
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Types of Engineered Objects

• Consumer products
 TV, cars, notebooks, cell phones, radio, printers, vacuum cleaners, refrigerators,
washing machines, etc.
 Off-the-shelf products
 The number of customers and manufacturers is large (>10)
• Industrial products
 Supercomputers, CNC machines, X-ray machines, MRI scanners, prostheses, wind
turbines, generators, etc.
 The number of customers and manufacturers is limited (2-10)
• Unique products
 Large Hadron Collider (CERN), nuclear power plants, nuclear submarines, rockets,
satellites, etc.
 Custom-made products
 The number of customers and manufacturers is very limited (1-2)

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Types of Plants and Facilities

• Plants produce variety of goods
 Mining (ore)
 Processing (pure metal, gasoline)
 Manufacturing (electronics, kitchen appliances, etc.)
 Power (electricity)
 Chemical (acid, gas)
• Facility produce variety of services Astana Power Plant
 Healthcare (hospital, clinic) https://az.wikipedia.org/wiki/Astana_Arena

 Transport (railway station, bus station, airport)

 Maintenance (car fix)
 Educational (school, university)
 Entertainment (movie, bowling center)
 Sport (arenas, tracks)

Astana Arena 13
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Performance of Engineered Objects

• Performance characterizes how well an engineered object performs
its intended functions.
 how well a person, machine, etc. does a piece of work or an activity
[Cambridge]
 the ability to perform [Merriam-Webster]
• Performance is a variable or a set of variables that depends on
 Perspective (customer or manufacturer)
 Operating environment
 Usage
• Failure – loss of performance.

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Maintenance Cost
• Maintenance is usually not applied to very cheap objects that are
available in the market.
• Maintenance cost consists of two major components: direct and
indirect costs.
• Direct costs are costs of performing maintenance.
 Example: cost of materials and space parts, labour, contractors, etc.
 Easy to calculate
• Indirect costs are financial loss due to failures.
 Example: loss of revenue to due production stops
 Difficult to calculate
 Often are higher than direct costs
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Effects of Maintenance Engineering

• The correct implementation of maintenance engineering techniques
achieves the following
 Prevent failures
 Save human lives and destruction of material
 Decrease production or service cost
 Increase product or service quality
 Optimize overall and individual processes
 Increase manpower and equipment utilization efficiency
 Increase lifespan of equipment
 Increase profits
 Improve competitiveness

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Maintenance Engineering in Future

• Technology becomes more complex. Subaru’s
 Maintenance cost increases “Ring of fire”
[1]
 Failures due to lack of maintenance cost even more
 Failures are becoming more difficult to detect
• Maintenance Engineering should be part of the design and production
strategy.
 In the past, design and maintenance were decoupled, as well as production strategy
and maintenance
• Maintenance is a complex issue and problem, it involves the following
aspect: financial (cost, budget), scientific (friction, forces, degradation),
engineering (manufacturing, components, design), customer (ease of
usage, frequency of maintenance), market, etc.
What examples can you give for bad design or
[1] https://www.gtplanet.net/forum/threads/worst-modern-engineering-design-decisions-on-automobiles.385950/ maintenance? 17
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Maintenance Engineering in Future

• Development of sensors, information, and communication
technologies lead to ease of maintenance and rapid development of
maintenance engineering.
• Internet of Things – network of different objects with sensors
connected to Internet.
• Big Data.
 Reason for inefficient management is lack of data
• Artificial Intelligence.
• Shift from reactive to proactive maintenance.

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https://www.linkedin.com/pulse/how-futuristic-future-technology-or%C3%A0tile-zungu/
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Questions?

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