Introduction to

Maintenance & Reliability

Engineering

DEVELOPMENT AND DEFINITION

DEFINITION OF RELIABILITY
The most important components of this definition must
be clearly understood to fully know how reliability
in a product or service is established:

Probability
Intended function
Satisfactory
Specific period of time
Specified conditions
DEFINITION OF RELIABILITY
DEFINITION OF RELIABILITY
• “ability
under of an itemfor
given conditions toa perform a required
given time interval” function
- IEC 60050

• “… the
function
stated probability
without
period that an
failure
of time…” itemstated
under will perform a required
conditions for a
- Smith, D.J. (2005)
DEFINITION OF RELIABILITY
So…Reliability…
• Can be
• perform defined
a be
conditions
Can also
A time for asstated
required
a -function
expressed
dependent The probability
thewithout
asperiod that
of time.
number
characteristic. of an under
failure item/system
failures stated
over will
a period.
• It can only
predicted be time.
at any determined after an elapsed time but can be
• It is
operate
life) the the
under probability
properly that a product
for a specified
design operating period or
ofservice
conditions time will
(design
without failure.
Development of maintenance & reliability
engineering
First generation maintenance (pre-WW2)

• Industry not highly mechanized so downtime

not particularly important.

• Most equipment simple and over-designed

• Reliable and easy to repair.
• Eventually just wore out.

• Only systematic maintenance required - simple

cleaning, servicing and lubrication.

• Philosophy: “Fix it when it breaks!”

Development of maintenance & reliability
engineering
Second generation maintenance (WW2 to mid-70’s)
• More mechanisation and concern over downtime.
• Idea that failures could and should be prevented.
• Awareness of “burn-in” failure mode
• Bath-tub curve
• Increase
operatingincosts.
maintenance costs as a proportion of total
• Development of first planning and scheduling tools.
• Philosophy: Preventative overhauls
Development of maintenance & reliability
engineering
Development of maintenance
3rd generation maintenance (mid-70’s +)
& reliability
engineering
• Aircraft data identifies 6 different failure mode patterns.
• Growth of mechanisation
availability and automation increases focus on plant
and reliability.
• Effect of failures on HS&E becomes important as regulations
tighten.
• Cost of maintenance
operating costs. increases: Often 1st or 2nd highest of all
• New techniques
maintainers to:become available to collect data that would enable
• To predict failures - Predictive Maintenance
• Optimise maintenance decisions - Asset Management
How reliability is measured?
• The probability of an item that does not fail in
a time interval (0,t), survival probability
• Beside
followingbeing
reliability measured
can as metrics:
a probability,
be quantified
parameters or via e.g. the
• Mean number of failures in a given time (failure rate)
• Mean timesuccessive
between between failures
failures.(MTBF) – the average time
• Mean timeuntil
elapses to failure (MTTF)
a failure - the average time that
occurs.
Objectives of Reliability Engineering
• To apply engineering knowledge and specialist
techniquesoftofailure.
frequency prevent or reduce the likelihood or
• To
do identify and correct
occur, despite of the the causes
efforts of failures
to prevent them.that
• To determine
occur, ways
if their of coping
causes have notwith
beenfailures that do
corrected.
• reliability
To apply data.
methods
of for estimating
new designs, and fortheanalysing
likely
•
Theory and basic concepts
• Qualitative reliability
• FTA, FMEA, FMECA
• Quantitative reliability
• Statistical reliability
• Physics-based reliability
• Maintenance
• Time-based maintenance
• Condition-based maintenance
Role of a Mechanic
and
the
Engineers
Todifferentiate
of understand
industry. more
engineering,
different it
or about
is
department reliability
important
describe working to
the roles
in
Role of a Mechanic
• makes routine inspections, documents inspections and repairs
• performs scheduled maintenance
• runs tests after making repairs or performing maintenance
Jobaon.
worked
fixing
properly.
replacing duties
broken
belts may
A Amechanic vary
mechanic
wing,
or based
working
repairing
working
repairing on
on which
paint
aonbroken
the the partmayofbethe
orexterior
securing
engine
part. of aplane
so is
plane
achanging
door the being
itmay be
seals
oil,
and An
FAA. A&Pregulations
FAA
repairs
equipment mechanic
made
and to must
ensures knowthe
govern
airplanes. and
regulations follow
maintenance
The all schedules,
FAAbeing
are regulations
conducts
met. set by on
regularinspections
checks the
 Role of an Engineer (Design)
• develop new technological solutions
•
•
•
includes defining problems
conducting and narrowing research
analyzing criteria
• finding and analyzing solutions and making decisions.
Much of an
applying,
engineers
behaviours,and engineer's
spend transferring
56% of
including time
14%their is
timespent
information.
actively on
engaged
searching researching,
Indeed,
in research
for various locating,
suggests
information
information.
Engineers
choose
crucial
the themust
and weigh
solution
unique
constraints
result. adifferent
that
on task is bestdesign
to identify,
design in choices
matches
order to on their
the produce a merits
requirements.
understand, and and
Their
interpret
successful
•
Role of an Engineer (Analysis)
Engineers apply techniques of engineering
analysis in testing, production, or
maintenance.
• supervise
elsewhere production in factories and
• determine the causes of a process failure
• test output to maintain quality.
• estimate
complete the time and cost required to
projects.