RELIABILITY, MAINTENANCE &

PLANT SERVICES

N.K.AGARWAL
 RELIABILITY
• PROBABILITY THAT THE DEVICE OR THE SYSTEM WILL
PERFORM ITS INTENDED DESIGN FUNCTION FOR A
SPECIFIED PERIOD OF TIME UNDER SPECIFIED
ENVIRONMENTAL CONDITIONS
• BASIC FACTORS ASSOCIATED WITH RELIABILITY
– OPERATING CYCLE OR FUNCTION
– TOLERANCE OR ACCURACY OF THE OUTPUT FUNCTION
– OPERATING TIME
– AMBIENT ENVIRONMENTAL CONDITIONS
• RELIABILITY IS THE PROBABILITY OF THE EVENT AND
FOR ANY DEVICE, IT WILL BE A NUMBER IN THE RANGE
FROM 0 TO 1
 RELIABILITY AND RISK

• CLOSELY RELATED
– RISK OF POOR QUALITY CONCERN BOTH , THE
PRODUCER AND CONSUMER
• RISK FROM PRODUCER’S POINT OF VIEW
– COMPETITION
• HIGHLY RELIABLE PRODUCTS OFFER A COMPETITIVE
ADVANTAGE
• HIGHLY UNRELIABLE PRODUCTS LOSE CUSTOMER
LOYALTY AND EVENTUALLY DISAPPEAR
– CUSTOMER REQUIREMENT
• CUSTOMERS REQUIRE HIGH RELIABILITY PRODUCTS TO
MINIMISE MAINTENANCE COSTS
 RELIABILITY AND RISK
– WARRANTY AND SERVICE COSTS
• UNRLIABLE PRODUCTS PUT FINANCIAL BURDEN OF WARRANTIES
ON THE PRODUCER
– LIABILITY COSTS
• FAILURES IN PRODUCTS RESULTING FROM MANUFACTURING /
DESIGN DEFECTS HOLD A PRODUCER LIABLE FOR THE DAMAGES
IN SOME COUNTRIES
• RISK FORM CONSUMER’S POINT OF VIEW
– SAFETY
• FAILURE OF EQUIPMENT LIKE AUTOMOBILES, TRAINS,
AEROPLANES RESULT INTO DEATH OF HUMAN BEINGS
– INCONVENIENCE
• MANY FAILURES OF EQUIPMENT OR SERVICES CAUSE
FRUSTRATION AND DELAYS TO CUSTOMERS E.G. DELAYS OF
BUSES AND TRAINS
– COSTS
• POOR RELIABILITY COSTS BOTH, PRODUCERS AND CUSTOMERS
 RELIABILITY FUNCTION
• INSTANTANEOUS RATE AT WHICH THE DEVICES
FAIL ‘’ IS CALLED FAILURE RATE ( OR %
FAILURE PER UNIT TIME PERIOD )
• MATHEMATICALLY, PROBABILITY OF
SUCCESSFUL OPERATION FOR t HOURS
R=e-∫0t dt
• IN USEFUL LIFE PERIOD, EQUIPMENT FAILURE
RATE  IS CONSTANT AND FAILURES ARE OF
RANDOM NATURE
R=e- t
 LIFE CHARACTERISTIC CURVE OF
DEVICES

INITIAL WEAR OUT

DEFECTIVES FAILURES

=CONSTANT

CHANCE
FAILURES

WEAR-IN OR INFANT USEFUL LIFE WEAR OUT

MORTALITY PERIOD PERIOD PERIOD
 FAILURE RATES
• UNITS ARE SPECIFIED AS
 =1%/1000 HRS=1 FAILURE/105 HRS=10X10-6 FAILURES/HR/PART
 = 1 BIT= 1 FAILURE/108 HRS=0.01X10-6 FAILURES/HR/PART
 =1X10-6 =1 FAILURE/106 HRS=1X10-6 FAILURES/HR/PART
• MEAN TIME BETWEEN FAILURE (MTBF) OF AN
EQUIPMENT
– DESIGNATED AS ‘m’ AND IS THE RECIPROCAL OF FAILURE
RATE
– m= 1/  HR
– FOR A NUMBER OF EQUIPMENT OPERATED DURING THEIR
USEFUL LIFE
m= TOTAL OPERATING TIME FOR ALL EQUIPMENTS
NUMBER OF FAILURES
 SYSTEM RELIABILITY EVALUATION

• SERIES SYSTEM

A B C K

– PRODUCT OF THE RELIABILITIES OF INDIVIDUAL ELEMENTS

– RS=RA*RB*RC*…..RK=e- st WHERE s IS THE SYSTEM FAILURE RATE
 SYSTEM RELIABILITY EVALUATION
• RELIABILITY OF REDUNDANT SYSTEMS
A

– RELIABILITY OF COMBINATION Rs (PROBABILITY THAT AT

LEAST ONE WILL OPERATE)
– RS+Qs=1 WHERE Qs=UNRELIABILITY OF PROBABILITY OF
FAILURE OF BOTH, AND
– Qs=QA*QB
– BUT QA=1-RA AND QB=1-RB
– HENCE Qs=(1-RA)(1-RB)
– AND RS =1-(1-RA)(1-RB)
• REDUNDANCY CAN SIGNIFICANTLY IMPROVE THE
RELIABILITY OF THE SYSTEM
 RELIABLE PRODUCT
• IMPORTANT AREAS TO TURN OUT A RELIABLE PRODUCT
– DESIGN OF PRODUCT
– PRODUCTION
– MEASUREMENT & TESTING
– MAINTENANCE
– FIELD OF OPERATION
• RELIABILITY OF SERVICES
– DIFFICULT TO ASSESS, BEING INTANGIBLE
• SOME EQUIPMNT BASED SERVICES E.G. ELECTRICAL,
TELEPHONES, TRANSPORT MEASURED AS ‘AVAILABLE TIME’,
‘FREQUENCY OF DOWN TIME’ ETC.
• PEOPLE BASED AS ‘HONESTY’, ‘RELIANCE’, ‘TRUSTWORTHY’ ETC.
 IMPROVING PRODUCT
RELIABILTY
• APPROACHES USED
– OVERDESIGN
• ENHANCING A DESIGN TO AVOID A PARTICULAR TYPE OF
FAILURE
– CHANGE OF MATRERIAL AND PROTECTIVE COATINGS FOR
CORROSION PROTECTION
– DESIGN SIMPLIFICATION
• REDUCTION OF NUMBER OF COMPONENTS IN A PRODUCT
– RELIABILITY IS THE FUNCTION OF THE PRODUCT OF
INDIVIDUAL COMPONENT RELIABILITY
– PROVIDING REDUNDANCY
• PROVISION OF RELIABLE COMPONENT BACK UP IN THE SYSTEM
– RELIABILITY IMPROVES THROUGH REDUNDANCY
 IMPROVING PRODUCT
RELIABILTY
– USE PROVEN DESIGNS
– USE OF HIGH RELIABILITY COMPONENTS
– USE FAIL-SAE METHODS, AND
– USE PROVEN PROCESSES / OPERATIONS
 PLANT MAINTENANCE
• FUNCTION OF THE MANUFACTURING MANAGEMENT
CONCERNED WITH THE DAY- TO- DAY PROBLEM OF
KEEPING THE PHYSICAL PLANT IN GOOD HEALTH
• AN ESSENTIAL ACTIVITY IN EVERY MANUFACTURING
ESTABLISHMENT
– NEEDED TO ENSURE AVAILIBILITY OF THE MACHINES,
BUILDINGS & SERVICES NEEDED BY OTHER PARTS OF THE
ORGANISATION FOR THE PERFORMANCE OF THEIR FUNCTIONS
AT AN OPTIMUM RETURN ON THE INVESTMENT, WHETHER
THIS IS IN MACHINES, MATERIALS OR EMPLOYEES
 MAINTENANCE
• SCOPE
– PRIMARY FUNCTION
• MAINTENANCE OF EXISTING PLANT & MACHINERY, BUILDINGS
& GROUND
• EQUIPMENT INSPECTION & LUBRICATION
• UTILITIES GENERATION & DISTRIBUTION
• ALTERATION TO EXISTING EQUIPMENT & BUILDINGS
• NEW INSTALLATION OF EQUIPMENT AND BUILDING
 MAINTENANCE
• SCOPE
– SECONDARY FUNCTION
• STORE KEEPING- STOCK OF SPARE PARTS
• PLANT PROTECTION INCLUDING FIRE SAFETY
• WASTE DISPOSAL
• SALVAGE
• INSURANCE ADMINISTRATION
• JANITORIAL SERVICES
• PROPERTY ACCOUNTING
• POLLUTION & NOISE CONTROL
 OBJECTIVES OF MAINTENANCE
• MINIMUM LOSS OF PRODUCTIVE TIME BECAUSE OF EQUIPMENT
FAILURE ( IDLE TIME OF EQUIPMENT)
• MINIMISING REPAIR TIME & COST
• MINIMISING LOSS DUE TO PRODUCTION STOPPAGE
• EFFICIENT USE OF MAINTENANCE PERSONNEL & EQUIPMENT
• PROLONGING LIFE OF CAPITAL ASSETS BY MINIMISING RATE OF
WEAR & TEAR
• TO KEEP ALL PRODUCTIVE ASSETS IN GOOD WORKING ORDER
• TO MAXIMISE EFFICIENCY & ECONOMY IN PRODUCTION THROUGH
REGULAR INSPECTION & REPAIR OF SAFETY DEVICES
• TO MINIMISE THE TOTAL MAINTENANCE COST WHICH INCLUDES
COST OF REPAIRS, COST OF PREVENTIVE MAINTENANCE &
INVENTORY CARRYING COST DUE TO SPARE PART INVENTORY
• TO IMPROVE QUALITY OF PRODUCTS & PRODUCTIVITY
 TYPES OF MAINTENANCE

• BREAK DOWN OR CORRECTIVE

• PREVENTIVE
• PREDICTIVE
• ROUTINE
• PLANNED
 BREAK DOWN MAINTENANCE

• MAINTENANCE DONE AFTER A BREAKDOWN

OCCURS
• A PASSIVE ROLE AIMED AT
– GETTING THE EQUIPMENT BACK INTO OPERATION AS
SOON AS POSSIBLE
– CONTROL COST OF REPAIRS
– CONTROL COST IN REPLACEMENT OF SPARE MACHINES
 PREVENTIVE MAINTENANCE

• UNDERTAKEN BEFORE THE NEED ARISES & AIMS

TO MINIMISE THE UN-ANTICIPATED OR MAJOR
BREAK DOWNS
– PROPER IDENTIFICATION OF EQUIPMENT
– ADEQUATE RECORD OF WORK, COSTS ETC
– INSPECTION SCHEDULE
– INSPECTION CHECK LISTS
– WELL QUALIFIED INSPECTORS
– USE OF REPAIR BUDGETS FOR MAJOR EQUIPMENT
– ADMINISTRATION PROCEDURES FOR FOLLOW UP
PROGRAMME
 PREDICTIVE MAINTENANCE

• MAINTENANCE BASED ON THE CONDITION OF

EQUIPMENT
• SENSITIVE INSTRUMENTS USED FOR PREDICTING
TROUBLE
• EXTENTION OF SERVICE LIFE WITHOUT FEAR OF
FAILURE
 ROUTINE MAINTENANCE

• PERIODIC INSPECTION, CLEANING ,

LUBRICATION & REPAIR OF PRODUCTION
EQUIPMENT
• CAN BE ON-LINE OR OFF-LINE
 PLANNED MAINTENANCE

• INSPECTION OF ALL PLANT & MACHINERY

ACCORDING TO PRE-DETERMINED SCHEDULE
– TO SERVICE , OVERHAUL, LUBRICATE OR REPAIR BEFORE
ACTUAL BREAKDOWN OR DETERIORATION OCCURS
– AIMS TO REDUCE MACHINE STOPPAGE DUE TO SUDDEN
BREAK DOWN
– REDUCES MACHINE BREAK DOWN TIME , COST OF
MAINTENANCE AND INCREASES PRODUCTIVITY
 MAINTENANCE POLICY
• WELL PLANNED MAINTENANCE DEPARTMENTS IN SMALL
PLANTS
• NON- PRODUCTION MAJOR ENGINNERING JOBS TO
MAINTENANCE DEPARTMENT IN LARGE COMPANIES
• WELL PLANNED EQUIPMENT MAINTENANCE PROGRAM TO
UTILISE & MAXIMISE LIFE OF EQUIPMENT OR POLICY OF
MINIMUM MAINTENANCE & MAXIMUM WEAR TO REPLACE THE
EQUIPMENT
• CONTRACT OUT SOME WORK DURING PEAK PERIODS TO AVOID
GETTING TOO FAR BEHIND & ALSO AVOID HIRING TEMPORARY
EXTRA HELP
• DEFER SOME MAINTENANCE WORK UNTIL SLACK PERIOD SO AS
TO KEEP THE WORK FORCE INTACT DURING SUCH PERIODS
• REPLACE MACHINES & EQUIPMENT AT OPTIMUM TIME BEFORE
THEY GET TOO OLD & REQUIRE TOO MUCH REPAIR WORK
 ECONOMICS OF MAINTENANCE
• TOTAL COST DECREASES UPTO SOME POINT WITH
INCREASING PREVENTIVE MAINTENANCE
• BEYOND THIS, INCREASINGLY HIGHER LEVELS OF
PREVENTIVE MAINTENANCE RESULT IN HIGHER
PREVENTIVE MAINTENANCE AND TOTAL
MAINTENANCE COST
– NOT ECONOMICALLY JUSTIFIED
• LEVEL OR DEGREE WITH THE TOTAL MINIMUM
MAINTENANCE COST IS KNOWN AS OPTIMUM LEVEL
OF MAINTENANCE ACTIVITY OR IDEAL LEVEL OF
MAINTENANCE
– AT THIS LEVEL, THE PEVENTIVE MAINTENANCE COST
EQUALS THE BREAK DOWN MAINTENANCE COST
OPTIMUM LEVEL OF MAINTENANCE
TOTAL MAINTENANCE COST
ANNUAL COST

PM COST

BREAKDOWN MAINTENANCE COST

OPTIMUM LEVEL OF MAINTENANCE

DEGREE OF MAINTENANCE
 ESTIMATION OF
BREAK DOWN COSTS

• WITH GOOD RECORDS AVAILABLE FOR

FREQUENCY & COST OF BREAK- DOWN IN THE
PAST,
– USING A SIMPLE CONCEPT OF EXPECTED VALUE,
• CURRENT BREAK DOWN POLICY CAN BE COMPARED
WITH A GIVEN MAINTENANCE POLICY
 RELIABILITY AND
MAINTAINABILITY
• RELIABILITY IS CONCERNED WITH ELAPSED
TIME BETWEEN FAILURES OF A PRODUCT
• ISSUES OF RELIABILITY GET CLOSELY RELATED
TO MAINTENANCE AND MAINTAINABILITY
• AVAILABILITY OF AN EQUIPMENT FOR
OPERATION IS DETERMINED BY THE MEAN TIME
BETWEEN FAILURE AND MEAN TIME TO REPAIR
• AVAILIBILITY = MTBF / ( MTBF + MTTR )
 TOTAL PRODUCTIVE
MAINTENANCE (TPM)
• ORIGINALLY DEVELOPED IN JAPAN
• AN APPROACH BRINGING TOTAL QUALITY MANAGEMENT
CONCEPTS TO THE PRACTICE OF PREVENTIVE
MAINTENANCE
• INVOLVES THE CONCEPT OF REDUCING VARIABILITY
THROUGH EMPLOYEE INVOLVEMENT AND EXCELLENT
MAINTENANCE RECORDS
• METHOD DESIGNED TO ELIMINATE THE LOSES
– CAUSED BY BREAK-DOWN OF MACHINES AND EQUIPMENTS
• BY IDENTIFYING AND ATTACKING ALL CAUSES OF EQUIPMENT
BREAK-DOWNS AND SYSTEM DOWN TIME
 TOTAL PRODUCTIVE
MAINTENANCE (TPM)
• SPECIFIC ACTIONS OF TPM
– RESTORING EQUIPMENT TO A LIKE-NEW CONDITION
– HAVING OPERATORS INVOLVED IN THE MAINTENANCE
– IMPROVING MAINTNANCE EFFICIENCY AND
EFFECTIVENESS
– TRAINING THE LABOUR FORCE TO IMPROVE THEIR JOB
SKILLS
– MINIMISE MAINTENANCE EFFORTS
– EFFECTIVE USE OF PREVENTIVE AND PREDICTIVE
MAINTENANCE TECHNOLOGY
TOTAL PREVENTIVE MAINTENANCE

• TOTAL PREVENTIVE MAINTENANCE ( TERM

GENERALLY USED FOR TOTAL PRODUCTIVE
MAINTENANCE IN MANUFACTURING) IS THE
LATEST DEVELOPMENT IN THE EVOLUTION OF
MAINTENANCE METHODS
• INCLUDES
– REGULAR PREVENTIVE MAINTENANCE INCLUDING
HOUSEKEEPING
– PERIODIC PREFAILURE REPLACEMENT OR OVERHAULS,
AND
– INTOLERANCE FOR BREAK-DOWNS OR UNSAFE
CONDITIONS
TOTAL PREVENTIVE MAINTENANCE

• CONCEPT OF TEROTECHNOLOGY IS CONCERNED

WITH APPLICATION OF MANAGERIAL,
FINANCIAL, ENGINEERING AND OTHER SKILLS
TO EXTEND THE OPERATIONAL LIFE AND
EFFICIENCY OF EQUIPMENT AND MACHINERY
• TPM HELPS FOR THE SUCCESSFUL
IMPLEMENTATION OF TOTAL QUALITY
MANAGEMENTAIMED AT SATISFYING
CUSTOMER REQUIREMENT
 STRUCTURE OF TOTAL PREVENTIVE MAINTENANCE

MAINTENANCE

IMPROVEMENT PREVENTIVE CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE

MODIFICATION CONDITION, CONDITION, SCHEDULED, UNSCHEDULED,

RETROFIT SELF MONITOR, PERIODIC, BREAKDOWN,
REDSIGN SCHEDULED, STATISTICAL, FIXED EMERGENCY,
CHANGE ORDER MACHINE PREDICTIVE, INTERVAL, REPAIR,
CONTROL TREND, SPECIFIC TIME REMEDIAL
LIMITS ANALYSIS
CONCEPT OF TEROTECHNOLOGY, A MODEL OF TPM
6
RELATED SUBJECTS
AND PRACTICES

OPERATION DESIGN
1

INSTALLATION ACK
EDB
FE
TERO
2 TECHNOLOGY 5
REMOVAL OF PLANT ,
COMMISSIONING
MACHINERY / EQUIPMENT

3
PLANNED MAINT
PREVENTIVE 4
REPLACE MENT

CORRECTIVE
ROUTINE
ROUTINE LONG TERM
 FAULT TREE ANALYSIS
• TECHNIQUE DEVELOPED IN 1960s
• READILY ADOPTED BY A NUMBER OF WIDE RANGING
ENGINEERING DISCIPLINES AS ONE OF THE PRIMARY
METHODS OF PERFORMING RELIABILITY & SAFETY
ANALYSIS
• A DEDUCTIVE TOP DOWN METHOD OF ANALYSING
SYSTEM DESIGN AND PERFORMANCE
• INVOLVES SPECIFYING A TOP EVENT TO ANALYSE
( Ex. A FIRE)
• IDENTIFYING ALL THE ASSOCIATED ELEMENTS IN
THE SYSTEM THAT COULD CAUSE THAT TOP EVENT
TO OCCUR
 FAULT TREE ANALYSIS
• EVENTS AND GATES IN FAULT TREE ANALYSIS REPRESENTED BY
SYMBOLS
OR AND
• IN THE ANALYSIS, CERTAIN ELEMENTS OR EVENTS MAY NEED
TO OCCUR TOGETHER IN ORDER THAT TOP EVENT TO OCCUR
– THESE EVENTS ARE PUT UNDER AN AND GATE
• IF THE BASIC ELEMENT ALONE TRIGGERS THE TOP EVENT
– THESE ARE PUT UNDER AN OR GATE
• PROBABILITIES TO BE ADDED TOGETHER AT AN OR GATE TO
GIVE PROBABILITY OF THE NEXT EVENT
• PROBABILITIES TO BE MULTIPLIED AT AN AND GATE
• HUMAN ERROR CONTRIBUTION TO OVERALL SYSTEM
FAILURE CAN BE INCLUDED IN AN ANALYSIS IF HUMAN
ERROR PROBABILITIES ALSO DESCRIBED IN THE SAME TERMS
AS COMPONENT AND HARDWARE FAILURES
BENEFITS OF FAULT TREE ANALYSIS

• IDENTIFY POSSIBLE SYSTEM RELIABILITY OR

SAFETY PROBLEMS AT DESIGN STAGE
• ASSESS SYSTEM RELIABILITY OR SAFETY DURING
OPERATION
• IMPROVE UNDERSTANDING OF THE SYSTEM
• IDENTIFY COMPONENTS THAT MAY NEED TESTING
OR MORE RIGOROUS QUALITY ASSURANCE
SCRUTINY
• IDENTIFY ROOT CAUSES OF EQUIPMENT FAILURE
THANK YOU
 REFERENCES

• PRODUCTION OPERATIONS MANAGEMENT :

ASWATHAPPA
• TOTAL QUALITY MANAGEMENT :
K. SHRIDHARA BHAT
• MECHANICAL DESIGN & SYSTEMS HANDBOOK :
ROTHBART
• LECTURE NOTES FOR VARIOUS TRAINING
PROGRAMMES