Marine

Nama : Jamaluddin
NRP : 04211940005014

ME14 1329
Maintenance Management

Workbook 2:
Failure Characteristics
Course Instructor:
Dwi Priyanta
Department of Marine Engineering – ITS
2
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ME14 1329 Workbook 2 :
Maintenance Management Failure Characteristics

CONTENTS

1. Mechanism of Failure ......................................................... 3

2. Bathtub Curve ..................................................................... 5
3. Failure Patterns : New Facts Finding ................................... 8
4. Failure Prevention Tactics Based on Its Failure Pattern ........ 9
5. Failure Prevention tactics : Lesson Learned ....................... 10
6. Basic Maintenance Strategies............................................. 11
7. Maintenance : Why Bothers? ............................................. 13
8. Reference .......................................................................... 14

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1. Mechanism of Failure

Figure 1 Mechanism of Failure

Figure 1 above depicts the mechanism of failure of an equipment.

Read John Moubray’s RCM book Chapter 7 (RM03-01). Write down
the following definitions.
a. Potential Failure
The point in the deterioration process at which it is possible to
detect whether a failure is occurring, or is about to occur, is
known as potential failure. Potential failure point can be defined
also as the point in which the deterioration in condition or
performance can be detected.
b. Failure
The term failure means the component/machine fails functionally.
c. Functional Failure
A functional failure is defined as the inability of an asset to fulfill
one or more intended function(s) to a standard of performance
that is acceptable to the user of the asset
d. P-F Interval
The P-F interval is the time or cycles between the initial
detection of the potential failure condition and the time of
the actual functional failure.

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From Figure 1 on Page 3, at least there are four key interesting

questions which are strongly related to the maintenance activities or
maintenance strategies. Those questions are following.

Jawab :
1. When will failure be occurred?
Failure occurs when an asset or component cannot perform its
function. It starts when potential failures are detected. It can be
seen in Figure 1 that the failure occurs at point F
2. Is there any failure pattern?

3. Can potential failure be predicted?

A potential failure is an identifiable condition which indicates that
a functional failure is either about to occur or in the process
ofoccurring
In practice, there are thousands of ways offinding out if failures
are in the process of occurring.
4. Can failure be prevented?
On-condition tasks entail checking for potential failures, so that
action can be taken to prevent the functional failure or to avoid
the consequences of the functional failure

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2. Bathtub Curve
The classical view on how to describe an equipment lifetime was by
using a bathtub curve. The bathtub curve actually is a failure rate versus
time graph. The abscise of the graph represents the time (t) while the
ordinate represents the failure rate (z(t)). Figure 2 shows the bathtub
curve.

Z(t) Region 1 Region 2 Region 3

Increasing
Infant Mortality Mortality Rate
Period Useful Life Period
Period

t
Figure 2 Bathtub Curve

The bathtub curve was initially used to represent the mortality rate of
the population. The curve can be divided into three regions. Region one,
which is the left part of the curve, represents the infant mortality rate.
Since this curve was generated very long time ago when medical
technology was not so advance as today’s, therefore at the early life of
an infant there was a little probability that the baby would survive or
the probability of the baby being deceased was so great. That is why
the first region of the bathtub curve is also well known as infant
mortality period.

As the baby grown up to be a child, the mortality rate was also

decreased at certain level and the second period of the bathtub curve
was started. Starting at this period, the child started to grow up to be
teenager and finally to be a mature man. During these periods, the
survivors already have good immunity to common diseases. Only extra
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ordinary conditions and situations which were random in nature could

make the survivors deceased. At these periods, all survivors were in
their useful life periods. That is way this region is also known as useful
life period.

If the survivors were survived until the end of the second period, which
mostly were grandfathers or grandmothers, it could be expected that
the mortality rate would be increased as time goes by. That is way this
region is also known as increasing mortality rate period.

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In early 40’s reliability engineers adopted the bathtub curve to describe

the lifetime of an equipment. Discuss with your group how to interpret
the bathtub curve from the point of view reliability engineers. To make
your discussion focus, use Table below to capture key issues addressed
in each region of the bathtub curve.

Region I Region II Region III

Well Know as  Infant mortality  Useful life  Increasing
period period mortality period

Failure Failures in Region In Region II useful In region III, the

Characteristics 1 have low life failure does not character of failure
potential and more affect the system will stop the total
difficult system due to
maintenance. component
resilience
Failures Caused Failure is caused Failure was caused Failure is caused
by by errors in system by an over working by the resilience of
manufacturing system so that the components of the
from design to system failure was system due to
components not in accordance maintenance or
with the plan. according to time.

Failure rate can Correct design Using the system Using a system
be reduced by planning, selection in operational with below the
of quality conditions by actual operational
components and maintaining system time and
have high capabilities and not replacement of
reliability. over working. components on a
schedule.

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3. Failure Patterns : New Facts Finding

Engineering systems has been developed more sophisticated and
complex and so did the failure pattern of the equipment. This will also
make the changes of maintenance techniques and strategies.

Read John Moubray’s RCM book Chapter 1. Moubray explained that the
maintenance era could be divided into three generation, they were the
first, the second and the third generation. Discuss with your
group :
a. How the expectation of maintenance growing from the first to
the third generation ?.
Answer : Expectations regarding maintenance and repair are
divided into 3 generations. The first generation around the
1940-1950 period, namely the use of the maintenance system,
still expected that only if there was damage it would be
repaired, so it had not taken into account how to reduce the
operational availability of the system for a longer period of
time. For the second generation in the 1960-1970 period using a
better principle because the expectations of the system have
taken into account how the availability of the system to operate
has a longer time and has taken into account the lower costs. In
the third generation, namely the period around 1980-2000, the
expectations have taken into account higher availability and
reliability, safety, impact on the environment, tool life, and
expenditure efficiency.
b. How view on failure patterns changing from the first to the third
generation?
Answer: Failure patterns in three periods, namely in the first
period around 1940-1950, which has patterns on the
representative bathtub curve, which is not having early
mortality but relatively short useful life and then touching
mortality again, in the second period, around 1960-1970, there
are patterns. The mortality range in the early days is because
there are components that are improved so that there is a risk

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of failure, but the useful life length increases along with the
improvement of the components and then there will be a
mortality range. Then in the third generation the period 1980-
2000 has 6 different patterns because in the third generation
the use of the system is really planned in such a way that the
useful life adjusts the function of the system.
c. How maintenance techniques changing from the first to the
third generation?
Answer: In the first generation, the use of existing techniques is
only if the system is damaged it will be repaired, without any
planning regarding maintenance schedules and so on. For the
second generation, the technique used is to start with a
schedule for dismantling and maintenance, then there is a plan
for use in operations, and the use of computerization but with
inefficient technology. In the third generation, the technique
has developed with system condition monitoring, reability and
maintainability design, research on the hazards caused, failure
and effect analysis, an expert system and using a lot of skill and
teamwork.

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4. Failure Prevention Tactics Based on Its Failure

Pattern

Read John Moubray’s RCM book Chapter 1 (RM03-01). And Campbell’s

Uptime book Chapter 4 (RM03-02). There are six different failure
patterns exist.

a. Worst old failure rate pattern.

- age-related failures
- rapid increase in failures at a particular point of use
- the least common failure mechanism of all
- routine maintenance based on time is effective
- examples include impellers, crusher jaws, tracks,
b. Bathtub failure rate pattern.
- hight probability of failure at the begining and end of its life
- two tactics, at least, are necessary to deal with early end-of-life
problems
- it is a combination of "worst new" worst old
- an example is simple electromechanical systems
c. Slow aging failure rate pattern.
- associated with corrosion creep
- usually when equipment is in contact with the product
- use rebuild or component replacement lactic
- pipes, refractories, tires, structural, clutches, for example
d. Best new failure rate pattern.
- not age-related, except at begin ing of life
- age-based routine maintenance generally ineffective
- as with all random mechanisms, on condition the best tactic
- hydraulics, pneumatics are examples
e. Constant failure rate pattern.
- random failures, not age-related
- complex equipment systems: electronic, electric, mechanical
- routine age-related maintenance is ineffective
- ball bearings are the classic example
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f. Worst new failure rate pattern.
- most common failure mechanism for complexequipment
- probability declines with age, perhaps because of design,
manufacture, construction, or management
- once the infant mortality problem is solved, routine
maintenance plays a minor role
- electronics, avionics, highly complex/integrated equipment

Discuss with your group, for each failure pattern identified, determine
the appropriate maintenance tactics to prevent failure being happened
in each identified failure pattern.

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5. Failure Prevention tactics : Lesson Learned

This study gives us some important tips about how equipment should
be maintained:
 Failure isn't usually related directly to age or use.
 Failure isn’t easily predicted, so restorative or replacement
maintenance based on time or use won’t normally help to
improve failure odds.
 Major overhauls can be a bad idea because we end up at a
higher failure probability in the most dominant patterns.
 Age-related component replacements may be too costly for
the same reason.

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6. Basic Maintenance Strategies

So far, you have learned the failure patterns and failure prevention
tactics based on their failure patterns. Discuss with your team how to
develop a diagram represents basic maintenance strategies. To make
your discussion focus, use the following terminologies.
a. Calendar Based Maintenance
b. Condition Based Maintenance : The maintenance that is
initiated as a result of knowledge of the condition of the
item from routine or continuous monitoring.
c. Corrective Maintenance : The maintenance carried out after
a failure has occurred, and intend to restore the item to a
state in which it can perform its required function.
d. On Line Measurement
e. Periodic Inspection
f. Periodic Measurement
g. Periodic Testing
h. Planned Maintenance : the maintenance organized and
carried out with forethought, control and to a
predetermined plan
i. Preventive Maintenance : the maintenance carried out at
predetermined intervals (scheduled maintenance) or
corresponding to pre-described criteria (condition based
maintenance).
j. Running Hour Based Maintenance
k. Scheduled Adjustment
l. Scheduled Maintenance : The maintenance that is carried
out to a predetermined interval of time, running hours, etc.
m. Scheduled Replacement
n. Unplanned Maintenance : the maintenance carried out to
no such predetermined plan.

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7. Maintenance : Why Bothers?

So far, you have learned the failure patterns, failure prevention tactics
based on their failure patterns and basic maintenance strategies.
Discuss with your team why we need to perform maintenance tasks to
the physical assets.

There are many reasons why physical asset management has today
become the more essential part of management activities e.g.:
- attitudes towards physical assets have changed - nowadays it is more
common that the length of the ownership is not the same as the length
of the whole item life,
- aging of asset systems,
- increased pressure to improve added value of maintenance,
- increased requirements from the safety and environmental point of
view,
- 'silo' behaviour which keeps maintenance and other life cycle
processes separated,
- Higher return on physical assets
- Lower safety and environmental risk
- Higher efficiency and effectiveness of operations

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8. Reference

UPTIME : Strategies for Excellence in Maintenance Management, John

Dixon Campbell, Productivity Press, 1995.

MAINTENANCE EXCELLENCE : Optimizing Equipment Life-Cycle

Decisions, Edited by John Dixon Campbell, Andrew KS Jardine, Marcel
Decker, Inc., 2001.

RELIABILITY-CENTERED MAINTENANCE II, John Moubray, Industrial

Press, 1997

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