Reliability R(t)

Key Performance Indicators (KPI)

RAMS
 KPI

What you can’t measure , you can’t control

What you can’t control , you can’t manage

What you can’t manage ,you can’t improve

Machines List
Structure Diagram for all M/Cs
M/C

mech.1 mech.2 mech.3

Sys.1 Sys.2 Sys.3

equ.1 equ.2 equ.3

part.1 part.2 part.3

Data Recording
M/C Mechanism Equipment part Total Time (hr) Down Time(hr)
P.1 6000 0.5
Equ.1 P.2 6000 0.25
P.3 6000 0
P.1 6000 0
Mech.1 Equ.2 P.2 6000 1
P.3 6000 1.25
P.1 6000 0.5
Equ.3 P.2 6000 0.3
P.3 6000 0.6
M/C.1
P.1 6000 0.1
Equ.1 P.2 6000 0.55
P.3 6000 0.78
P.1 6000 0
Mech.2 Equ.2 P.2 6000 0
P.3 6000 0
P.1 6000 0
Equ.3 P.2 6000 0.9
P.3 6000 0.15
 Reliability
Reliability R(T) : is probability of zero failure during standard time
according to standard working conditions .

Reliability is a Dynamic aspect of

Quality

−λ 𝑡
R(t) = 𝑒
Mean Time between Failures (MTBF)
It is a Basic measure of Reliability for repairable product ,can be measure for
m/c or part

𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒−𝑢𝑛𝑝𝑙𝑎𝑛𝑛𝑒𝑑 𝑡𝑖𝑚𝑒 𝑇𝑇−𝐷𝑇

MTBF = =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒 𝑛𝑜.𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠

1
Failure rate =λ=
𝑀𝑇𝐵𝐹

1
−λ𝑡 − 𝑡
R(t) = 𝑒 =𝑒 𝑀𝑇𝐵𝐹
Case study 1

Total working hours = 100,000 hours

Number of failures = 20

MTBF = 100,000/20 = 5,000 hr/failure

Failure Rate = 1 / MTBF =20 /100,000 =0.0002

Sol:
R(t)=e ^(-0.0002*t)
At t = 5000 hour
R(t) = 36.7%
Case study 2
Total working hours = 100,000 hours
Number of failures = 20

MTBF = 100,000/20 = 5,000 hr/failure

Failure Rate = 1 / MTBF =20 /100,000 =0.0002 failure/hour
What is the planned duration T for R>50%

Sol:
1
−λ 𝑡 − 𝑡
R(t) = 𝑒 =𝑒 𝑀𝑇𝐵𝐹
−0.0002 𝑡
0.5 = 𝑒
T = 3460 hr
Reliability R(t)
System Reliability :
Series system :
Rs=RA * RB
= 0.9*0.9 = 0.81
Parallel system :
Rs=1-(1-RA) * (1-RB)
=1-(1-0.9) * (1-0.9) = 0.99
Backup system :
Rs=RA+RB(1-RA)
=0.9 +0.9(1-0.9) = 0.99
Case study 3

Diesel engine Pump

working condition=5years*4000 hr/year = 20,000 hours

Number of failures: Diesel engine coupling pump
4 2 5

Based on this information, Discuss the following :

1-MTBF for each part
2-calculate the failure rate for each part
3-After 1000 working hours , calculate the Reliability
 Diesel engine Pump

working hours no.of failures MTBF Failure rate R(t)

Diesel engine 20000 4 5000 0.0002 81.87%

coupling 20000 2 10000 0.0001 90.48%

pump 20000 5 4000 0.00025 77.88%

system 20000 11 1818 0.00055 57.69%

How to improve the system reliability
 Improve the maintenance program.
 Improve the manpower skills through advanced training plan.
 Use of backup components.
 Improve the mistake proofing (Poka -Yoke).