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Part Two (3 Reliability.... )
Part Two (3 Reliability.... )
Part Two (3 Reliability.... )
Availability
Need for reliability
Bathtub hazard rate concept
General reliability analysis formula
Reliability network and Evaluation tool
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Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
3
Learning Objectives
When you have read through and understood this material, you
should be able to:
Know the definition of reliability and the factors associated
with it.
Understand the concepts of Reliability, Availability and
Maintainability Engineering.
Know the techniques for Reliability analysis.
Calculate the failure rate under different conditions.
Understand the failure and reliability curves as a factor of
time.
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
4
Reliability Definition
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
5
The Reliability definition has four important elements:
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning
course.
course.
6
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
7
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
8
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
Basic Reliability Terms 9
Reliability: an introspection
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
12
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
13
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
14
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
15
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
16
Failure rate over the life of a product
Chart Title
Infant Mortality Wearout
Useful Life
D
A
Failure Rate
B C
Time
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
Bathtub Curve. 17
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
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18
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
Managing Reliability 19
Reliability Characteristics
Non-Repairable Systems:
Reliability=Availability
Failure Rate
MTTF
Time to First Failure
MRL (Mean Residual or remaining Life)
Repairable Systems:
Availability …. (Function of Reliability and
Maintainability)
Failure Rate and Repair Rate
MTBF
MRL (Economic Justification)
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.
21
Failure Rate for Repairable and Non-repairable
systems
MTBF θ = Total time Total Number of failures
Average Failure Rate = 1 θ θ = 1
Example:
300 cars have accumulated 45000 hours, 10 failures are observed.
What is the MTBF? What is the failure rate?
Note: considering Car as repairable system, Use MTBF
MTBF = 45000/10 = 4500 hours.
Average Failure rate = 10/45000 = 0.00022 per hour.
Five oil pumps were tested with failure hours of 45, 33, 62, 94 and
105. What is the MTTF and failure rate?
Note: considering pumps as non repairable systems, Use MTTF.
MTTF = (45+33+62+94+105) / 5 = 67.8 hours
Failure rate = 5 / (45+33+62+94+105) = 0.0147 per hour.
Note that MTTF is a reciprocal of failure rate.
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
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course.
course.
Example 22
Introduction
Introduction
to Reliability
to Reliability
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23
Example:
50 components are tested for two weeks. 20 of them fail in this
time, with an average failure time of 1.2 weeks.
Answer:
No. Of failures = 20
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning
course.
course.
24
Calculating failure rate from historical
information.
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning
course.
course.
25
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
Reliability function and failure rate 26
Reliability function
Probability of surviving at least till age t, i.e., that failure time is later than t
t
R t P (T t ) f (t )dt 1 f (t )dt 1 F (t )
t 0
Failure rate
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning
course.
course.
27
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
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Example 28
Trial data shows that 105 items failed during a test with a total
operating time of 1 million hours. (For all items i.e. both failed and
passed). Also, find the reliability of the product after 1000 hours i.e. (t) =1000
105
The failure rate 1.05 x104 per hour
1000000
Reliability at 1000 hours e t
(1.05 x104 x1000) = 0.9
R(1000) e
Therefore the item has a 90% chance of surviving for 1000 hours
Introduction
Introduction
to Reliability
to Reliability
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Engineering e-Learning
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29
Example
The chart below shows operating time and breakdown time
of a machine.
Introduction
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30
Contd..
= 4 / 136.9 = 0.02922
Therefore;
q = MTBF = 1/ = 34.22 hours
R = 55.74%
Introduction
Introduction
to Reliability
to Reliability
Engineering
Engineering e-Learning
e-Learning course.
course.
Maintainability 31
Introduction
Introduction
to Reliability
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32
OBJECTIVES OF MAINTAINABILITY
Introduction
Introduction
to Reliability
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33
ADVANTAGES OF MAINTAINABILITY
PREDICTION
Introduction
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34
n
i Rpi
i=1 n = number of subsystems
MTTR = i = Failure rate of the i th
system Rpi = Repair Time for the i
n
th
unit
i
i=1
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Where:
t = Allowable downtime
MTTR= Expected downtime (MTTR)
Introduction
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36
Mean-Time-To-Repair
The total corrective maintenance time divided by
the total number of corrective maintenance
actions during a given period of time.
Introduction
Introduction
to Reliability
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37
Availability
Introduction
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Inherent Availability (AI) 38
This is the ideal state for analyzing availability. The only considerations are
the MTBF and the MTTR. This measure does not take into account the
time for preventive maintenance and assumes repair begins
immediately upon failure of the system.
This can also be defined as steady – state availability.
The measure for inherent (potential) availability (A I) is :
MTBF
=
AI = + MTTR + MTBF
Introduction
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Achieved Availability (AA) 39
MTBMA
AA=
MTBMA + MMT
Where : MTBMA is the mean time between maintenance actions both preventive
and corrective.
MMT is the mean Maintenance Action Time, and MMT is further
decomposed into the effects of preventive and corrective maintenance and is
given as:
Introduction
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40
F c M ct + F p M pt
MMT =
Fc + Fp
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41
110
Then determine A A : A A = = 0.988 or 98.8%
110 + 1.33
Introduction
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to Reliability
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42
Operational Availability ( A 0)
168
= 0.977 or 97.7%
Solution : Ao= 168 + 4
Introduction
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43
MTBF
A= =
+ MTTR + MTBF
When t is large, the expression reduces to : A
=
+
Introduction
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to Reliability
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Engineering e-Learning
e-Learning course.
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44
3 5
{( ) ( ) * e( 1.6) } = .501
8 8
Introduction
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Other configurations to consider: 45
Series Configuration
A B C ….. n
n i
A = Ai =
I=1 i + i
Parallel Configuration
A
n i
B A=1-
i + i
I=1
Introduction
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46
( )( )
Solution: n i 1 2
A=1- =1-
i + i 1 + 1 2 + 2
i=1
Introduction
Introduction
to Reliability
to Reliability
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47
Distribution Analysis
You will study this topic in detail, in the RAMS training courses.
Introduction to Reliability
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48
Data Collection
Minimum Data Needs for each item
• Design Configuration
• When Produced
• How Many Produced
• Total Population
• Or Sample Population being studied
• When Entered Service
• When Failed
• How Many Failed
Introduction to Reliability
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49
Suggested Reading. (REFERENCES).
Ireson, William Grant, Clyde F Coombs, and Richard Y Moss. Handbook of
Reliability Engineering and Management. 2nd Edition. New York: McGraw Hill,
1996.
Nelson, Wayne. Accelerated Testing: Statistical Models, Test Plans, and Data
Analysis. Edited by S S Wilks Samuel. Wiley Series in Probability and
Mathematical Statistics. New York: John Wiley & Sons, 1990.
Introduction to Reliability
Introduction Engineering
to Reliability Engineering e-Learning
e-Learning
course.
course.