Countering technical failures in

Delhi Metro Using Data Science

MOHIT KUMAR
SR. CRA
19440
9711754512
Problem : Abrupt failure of equipment

Mohit Kumar
 Delhi Metro has been instrumental in ushering in a new era in the sphere
of mass urban transportation in India.
 But unanticipated technical failures impedes with our Vision, “Commuting
experience in Delhi Metro to be customer’s delight.”
 Frequent and lasting technical snags not only result in monetary loss for
organization, but also raises reliability and punctuality concerns.
Solution : Incorporating Predictive Maintenance
along with Preventive Maintenance

Mohit Kumar
 Predictive maintenance is used for identifying potential failures of assets that may occur while
checking the assets when they are running.
 It uses data analysis tools for controlling the performance and condition of equipment during
normal operation to reduce the probability of failures.
 It is a technique in which the service period of crucial parts is predicted on an inspection basis so
that the parts can be useful within the limit of their service period.
 Studies have shown that businesses across all sectors of industry can reduce equipment
maintenance costs by 12 to 18% by investing in Predictive maintenance and tracking failure rates
 Preventive maintenance refers to regular, routine maintenance to help keep
equipment up and running, preventing any unplanned downtime and expensive

Mohit Kumar
costs from unanticipated equipment failure.
 Preventive maintenance involves a systematic analysis of equipment where
potential malfunctions are detected and corrected to prevent equipment failure.
 A preventive maintenance schedule may include things such as cleaning,
lubrication, oil changes, adjustments, repairs, inspecting and replacing parts, and
partial or complete overhauls that are regularly scheduled.
Predictive Maintenance
It is performed to predict failures that might occur
No downtime of machine is required, i.e. one does not
need to stop main functions of assets as this
maintenance can be performed while assets are
performing their regular functions.
Maintenance occurs only when potential failures are
identified.
It is more complex and difficult than preventive
maintenance.
This maintenance action is less costly than preventive
maintenance as one can simply reduce, avoid
maintenance that is not necessary and thus reduce
maintenance costs.
It is less time-consuming as in this type of
maintenance, one needs to perform inspection and
maintenance only when required.
Preventive Maintenance
It is performed to prevent assets from unexpected
failures.
One needs to increase downtime of the asset to carry
out maintenance, i.e. one needs to stop main functions
of assets to carry out maintenance action.
Maintenance occurs even if potential failures are not
identified.
It is a less complex process and simple than predictive
maintenance.
This maintenance action is more costly than predictive
maintenance, as regular maintenance requires more
investment.
It is more time-consuming because in this type of
maintenance one needs to perform inspection and
maintenance regularly.
Why incorporate Predictive maintenance?

Mohit Kumar
 In any asset-intensive industry, reactive maintenance can interfere with
operational efficiency and profit margins.
 Incorporating Predictive maintenance along with Preventative maintenance
can yield significant financial and organizational benefits.
 Studies have shown that businesses across all sectors of industry can
reduce equipment maintenance costs by 12 to 18% by investing in
Predictive maintenance and tracking failure rates.
 How to implement?
• The process starts with identifying the problems to solve. The problem should
Identify Problems
be broad and broken down into specifics.
• Once the problems are identified, the data needs to be collected for analysis.
• If the data will not be available, in such case, infrastructure to collect data
Identify data required
needs to be built.
• While building the infrastructure and processes, attempt can be made to
enhance the utility of such infrastructure/processes. This can be done by Build infrastructure
assessing other possible utilities of the data collected. to collect data

• If the marginal cost of adding more data to solve a significant problem is low, it
can be pursued. Collect , Clean and
• Once the data starts getting collected, it needs to be cleaned and visualized. visualize data

• The dashboards and visualizations are to be followed by the creation of

predictive model(s), which are to be tested, reviewed and deployed. Build and test models

Review and deploy

 Failure data collection

Mohit Kumar
There are 5 key metrics to failure data collection.
 Mean Time To Repair (MTTR)
 Mean Time Between Failure (MTBF)
 Mean Time to Failure (MTTF)
 Planned maintenance percentage (PPC)
 Planned maintenance compliance (PMC)
 Mean Time To Repair (MTTR)

Mohit Kumar
 MTTR , Mean Time To Repair is a measure of the average time that elapses
between the discovery of equipment breakdown and the equipment's return to
operational status.
 This includes the time it takes to troubleshoot the issue, the time spent in actual
repairs, and the time spent in testing before the machine or piece of equipment is
utilized again.
 It can be an invaluable aid in the decision making process regarding the repair vs
replace question, maintaining inventory levels of replacement parts and tools and
staffing levels.
Mean Time Between Failure (MTBF)

Mohit Kumar
 MTBF Mean Time Between Failure gives an indication not only of
the availability for each piece of operational equipment, but also the level
of reliability.
 MTBF measures the average elapsed time between equipment breakdowns.
 We can calculate MTBF by taking the total operational time of the machine in
question and dividing that figure by the number of failures within that time frame.
 While MTBF is not directly related to planned maintenance, it is extremely
helpful for determining the optimal frequency for certain tasks, such as equipment
inspections, lubrication, etc.
 MTBF works with repairable equipment.
 Mean Time to Failure (MTTF)

Mohit Kumar
 MTTF is a measure of the expected length of time a particular machine or piece of
equipment will stay operational.
 MTTF must be calculated as an average of multiple non-reparable units.
 Effective maintenance and using durable, high quality components in pieces of
production equipment can boost MTTF.
 It can give a good idea of how long components will last, which in turn can help
them to plan for downtime, keep a sufficient number of replacement parts on
hand, and analyze the pros and cons of sourcing the components in question from
a different supplier.
 MTTF focuses on non-reparable items.
Planned maintenance percentage (PPC)

Mohit Kumar
 Planned maintenance percentage gives a proportion of time spent on planned
maintenance compared with total maintenance time.
 If PPC numbers are sub-optimal, however, a detailed analysis of which systems
are suffering the majority of unexpected failures can help managers prioritize
areas of need, and implement strategies to mitigate the effect of unplanned
downtime.
 While PPC may be a broad metric, it can give a solid indication of how effective
current preventative maintenance program actually is.
 Planned maintenance compliance
(PMC)

Mohit Kumar
 Planned maintenance compliance is a measure of how well maintenance
department is performing their required tasks.
 It can give a percentage of completed work orders compared to total work orders
requisitioned.
 PMC is helpful in identifying maintenance staff's performance, and can also help
you to determine if staffing levels should be adjusted, or additional training
should be provided in certain areas.
 Conclusion

Mohit Kumar
 Since Preventive maintenance is not always needed, it could be unnecessary time
spent on a job.
 Our organization already has infrastructure in place for data gathering, therefore,
no new infrastructure is needed.
 With training, existing staff can be used to clean and visualize data at hand.
 Inventory can be managed more efficiently by predictive analysis of components
which are likely to fail.
 Preventive and predictive maintenance needs to be carried out as both techniques
are the two sides of the same coin but different altogether.
Thank you