Mechanical Maintenance and Fault Diagnosis

Part (2)

1. Essay Questions:

1. Define the term “Maintenance Engineering,” and discuss the main purpose of
maintenance.
2. Discuss the principle objectives of maintenance and the reasons for maintenance.
3. Illustrate the main activities involved in maintenance planning
4. Illustrate the principle objectives of maintenance planning.
5. Define the term “Reliability,” and discuss the strategic importance of maintenance and
reliability.
6. Define the terms “Availability” and “Maintainability” and discuss how they are related
to “Reliability.”
7. Discuss the different classifications of availability.
8. Illustrate the different types/approaches of maintenance.
9. Compare between planned and unplanned maintenance polices.
10. Why it is important to an organization to have preventive maintenance plan? And
what are the main activities involved in preventive maintenance programs?

2. Numerical Questions

1. For the reliability analysis, 300 diodes were placed for a life test. After 1500 hr, 16
diodes had failed and test was stopped. The times at which failures occurred are: 115,
120, 205, 370, 459, 607, 714, 840, 990, 1160, 1180, 1300,1380, 1414, 1449 and 1497
hrs. Determine the failure rate of the diodes.

2. In a survival test involving mechanical valves, 1000 valves are tested. On the average,
822 valves survive 400 cycles of operation, and out of theses, 411 valves survive 700
cycles of operation. What is the probability of valve surviving 400 cycles as well as
700 cycles of operation? What is the probability that a valve will survive 700 cycles of
operation if it has already survived 400 cycles of operation?

3. Four identical electronic units are connected in parallel. Each has a reliability of 0.9.
Estimate the probability of 0, 1, 2, 3, and 4 of these units remaining operative.

4. An equipment consists of 100 tubes. Twenty of these are connected functionally in

series (branch A). The branch A is in turn connected in series to a parallel combination
of branches B and C. The branch B and C contain 20 and 60 tubes respectively,

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 connected functionally in series. The reliability of each tube in branch A, B, and C
respectively is 0.95, 0.93, and 0.96. Calculate the overall reliability of the equipment.

5. A critical measuring instrument consists of two sub-systems connected in series. Sub-

system A and B have reliabilities 0.90 and 0.92 respectively for a certain operating
time. It is necessary that the reliability of the instrument be raised to a minimum value
of 0.917 by using parallel sub-systems of A alone. Determine how many units of A
should be used with one B to get a minimum reliability value of 0.98. What is the
actual reliability value obtained?

6. In a workshop, a minimum of two lathes are required to operate continuously to meet

the demand. The ratio of the repair rate to the failure rate of each lathe is 4. If the
workshop has three identical lathes, determine the probability that at least two of them
are available in the long run.

7. Two components each with MTBF of 1000 hours are connected in (1) active and (2)
standby redundancy. Determine the overall system MTBF.

8. An electrical supply system is subject to failure which causes loss of supply to the
consumer. The mean time between such failures is known to be 398 hr and the mean
time to repair the failures and restore the supply is known to be 2 hr. What is the
average value of the availability of the supply to the consumer over a long period of
time?

9. A computer has a MTTF = 34 hr and a MTTR = 2.5 hr. (a) what is the availability?
And (b) if the MTTR is reduced to 1.5 hr, what MTTF can be tolerated without
decreasing the availability of the computer?

10.If a transmitter is to be designed to have reliability greater than 0.90 over 100 hr and a
minimum availability of 0.99 over that period, determine the values of MTTF and
MTTR.

3. MCQ

1- Maintenance consist of the following action(s)

(A) Replace of component

(B) Repair of component

(C) Service of component

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 (D) All of the above

2- The time elapsed from the point the machine fails to perform its function to the
point it is repaired and brought into operating condition is known as:

(A) Down time

(B) Break Down time

(C) Both (A) and (B)

(D) Idle time

3- Belt of an electric motor is broken, it needs:

(A) Corrective maintenance

(B) Scheduled maintenance

(C) Preventive maintenance

(D) Timely maintenance

4- The ____ goes on increasing with the increase in degree of maintenance efforts.

(A) Cost of down time

(B) Cost of spares and maintenance

(C) Labor and Overhead Cost

(D) All of the above

5- With the increase in preventive maintenance cost, breakdown maintenance cost

(A) Increases

(B) Decreases

(C) Remain same

(D) Any of the above

6- (Down time in hours / Available hours) =

(A) Maintenance effectiveness

(B) Frequency of breakdown

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 (C) Effectiveness of maintenance planning

(D) None of the above

7- (Number of breakdowns / Available machine hours) =

(A) Maintenance effectiveness

(B) Frequency of breakdown

(C) Effectiveness of maintenance planning

(D) None of the above

8- The reliability of an operation is normally NOT improved by which one of the
following procedures?

(A) Building redundancy into the operation.

(B) Designing out fail points in the operation.

(C) Laying off employees who cause faults in the operation.

(D) Ensuring some activities in the operation are 'fail-safe'.

9- If a machine operator fails to clean or lubricate his or her machine in the

prescribed manner and it fails, this is an example of:

(A) A mistake

(B) A misjudgment

(C) An error

(D) A violation

10- For a system composed of 400 interdependent components that each have
individual reliability of .99, the overall system will be working for less than ________
of the time.

(A) 5%

(B) 25%

(C) 75%

(D) 50%

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11- If a batch of 200 electronic components is tested for 400 hours and 5 fail during
the test, what is the failure rate as a percentage?

(A) 2.5%

(B) 10%

(C) 5%

(D) 1.25%

12- For an automated pizza-making machine the individual component reliabilities

are as follows: Dough mixer = .95 Dough roller and cutter = .99 Tomato paste
applicator = .97 Cheese applicator = .90 Oven = .98 If one of these parts fails the
whole system will stop working. What is the reliability of the whole system?

(A) 0.90

(B) 0.905

(C) 0.805

(D) 0.855

13- When measuring failure, how often a failure occurs relates to what?

(A) Failure rate

(B) Availability

(C) Reliability

(D) Quality

14- The number of failures over a period of time is called:

(A) The failure rate

(B) The mean time between failures

(C) The average failure point

(D) None of the above

15- Which among the following exhibits inversely proportional relationship with the
reliability?

(A) Production cost

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 (B) Design and development cost

(C) Maintenance and repair cost

(D) All of the above

16- What is the failure cost of a product possessing reliability R=1?

(A) Zero

(B) Unity

(C) Infinity

(D) None of the above

17- Which type of availability deals with the probability of system operation and
functioning at the requisite level in an ideal environment without any consideration
of maintenance?

(A) Inherent availability

(B) Achieved availability

(C) Operational availability

(D) None of the above

18- What would happen, if equipment possesses reliability and maintainability to the
maximum extent in accordance to MTTR?

(A) Failure rate is higher & downtime is longer

(B) Failure rate is lower & downtime is longer

(C) Failure rate is higher & downtime is shorter

(D) Failure rate is lower & downtime is shorter

19- On which factors does the down-time of equipment at the maintainability phase,
depend?

(A) Design

(B) Installation

(C) Both a and b

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 (D) None of the above

20- Which type of maintenance is associated or concerned with an elimination of

failures during the operational level of equipment?

(A) Preventive

(B) Predictive

(C) Breakdown

(D) Capital