MAINTAINABILITY DESIGN CHARACTERISTICS AND SPECIFIC

CONSIDERATIONS
There are many maintainability-related system/item characteristics that must be emphasized during
design. Some of these are: modular design, interchangeability, displays, human factors, safety, test
points, standardization, controls, illumination, weight, lubrication, accessibility, installation, training
needs, adjustments and calibration, tools, labeling and coding, test equipment, manuals, work
environment, covers and doors, size and shape, failure indication (location), connectors, and test
hookups and adapters.
The most commonly cited /mentioned maintainability-related characteristics by professionals
involved with maintainability include: displays, controls, doors, covers, labeling and coding,
accessibility, test points, checklists, mounting and fasteners, handles, connectors, test equipment,

charts, aids, and manuals. Some of these factors are discussed below.

ACCESSIBILITY
This may be described as the relative ease with which an item can be reached for replacement,
service, or repair. Inaccessibility is a frequent cause of ineffective maintenance, thus an important
maintainability problem. Many factors can affect accessibility. Some of them are as follows
1. Location of item and its associated environment
2. Frequency of entering access opening
3. Distance to be reached to access the part of component
4. Type of maintenance tasks to be performed through the access opening
5. Visual needs of personnel performing the tasks
6. Types of tools and accessories required to conduct the specified tasks
7. Work clearances appropriate for carrying out the specified tasks
8. Degree of danger involved in using access opening
9. Mounting or packaging of items/parts behind the access opening
10. Required times for performing the specified tasks
11. Type of clothes worn by the involved personnel

Some guidelines for the design of access openings are as follows:

1. Design access openings for maximum convenience in performing the required
maintenance tasks.
 2. Design access openings so they are a safe distance from hazardous moving parts or high
voltage points.
3. Ensure that access openings occupy the same face as associated features such as displays,
controls, and test points.
4. Ensure that the location of access openings allows direct access to the parts or components
that will subsequently require some kind of maintenance.
5. Ensure that access openings will be accessible effectively under normal installation of the
equipment or system.
6. Ensure that the lower edge of a restricted access opening is no less than 24 in. or its upper
edge no more than 60 in. from the work platform or floor.
7. Ensure that heavy parts/units can easily be pulled out rather than lifted out.
8. Ensure that the location of accesses is compatible with height of work stands and carts
that will often be used.

Table presents minimum access size requirements, expressed in inches, for one-handed tasks to
be performed by a bare-handed maintenance person wearing regular clothes.

TABLE
Minimum Access Size Requirements, Expressed in Inches, for One-Handed
Tasks Performed by a Bare-Handed Maintenance Person Wearing
Normal Clothes
Dimensions in Inches

Task Description Height Width

Placing arm through access up to the shoulder (i.e., full 5 5

Placing arm through access up to the elbow 4 4.5
Inserting components/parts 1.75 4.5
Inserting a closed hand with thumb outside of fist 4.25 5.12
Inserting empty hand held flat 2.25 4.5
MODULARIZATION

Modularization may be described as the division of a product into functionally and physically distinct
units to permit removal and replacement. The degree of modularization in a system or product
depends on factors such as cost, practicality, and function. Every effort should be made to use
modular construction wherever it is logistically feasible and practical as it helps reduce training costs,
in addition to other concrete benefits.
Some advantages of modularization are:
1. relative ease in maintaining a divisible configuration,
2. less time-consuming and -costly maintenance staff training,
3. simplified new equipment design and
4. shortened design time,
5. easy to divide up maintenance responsibilities,
6. lower skill levels and fewer tools required,
7. existing product or equipment can be modified with the latest functional units replacing their
older equivalents,
8. fully automated approaches can be employed to manufacture standard “building blocks,” and
9. easy recognition, isolation, and replacement of faulty items leading to more efficient
maintenance, thus lower equipment downtime.

Disposable Modules
Disposable modules are designed to be discarded rather than repaired after a failure. They are used
in situations when repair is costly or impractical. Their advantages outweigh the disadvantages, and
maintainable modules require significant expenditure in materials, labor time, and tools.
The important benefits of a disposal-at-failure design include
1. simpler and more concise trouble-shooting approaches;
2. smaller, simpler, and more durable modules with a more reliable design;
3. fewer types of spare parts required;
4. reduction in required tools, personnel, facilities, and repair time;
5. improved reliability due to the sealing and potting methods; and
6. better standardization and interchangeability of modules.
Some of the drawbacks of a disposal-at-failure design are:
1. an increase in inventory required because of need to have replacement modules on hand at all
times,
2. inability to redesign disposable modules,
3. reduction in module performance and reliability because of production efforts to keep them
inexpensive to justify their disposal,
4. reduction in available data on maintenance and failures, and
5. increase in unnecessary replacements.

Important Guidelines for Designing Modularized Systems or Products Guideline Description

1. Divide the product /system /equipment under consideration into many modular units. Make
modules/parts /components as uniform in size and shape as feasible.
2. To the extent possible, design the modules for ease of operational testing when removed
from the system or equipment.
3. Design all equipment so that an individual can easily replace any failed part.
4. Take an integrated approach to design by considering the problems of component design,
modularization, and materials simultaneously.
5. Aim to make each module capable of being inspected independently and effectively.
6. Design each modular unit small and light enough so that a single individual can easily handle
and carry it.
7. Ensure that the functional design of the equipment is matched with division of the equipment
/product into removable and replaceable items.
8. Emphasize modularization for forward levels of maintenance to enhance operational
capability. Design control levers and linkages in such a way that allows easy disconnection
from parts or components, in turn, simplifying component replacement process

INTERCHANGEABILITY
Interchangeability may be defined as an intentional aspect of design; any part / component /unit
can be replaced within a given item by any similar part /component / unit. There are two distinct
types of interchangeability: physical and functional. In physical interchangeability, two items can be
connected, used, and mounted in the same location and in the same manner. With functional
interchangeability, two given items serve the same function.
The basic principles of interchangeability include: liberal tolerances in the items requiring
frequent replacement and servicing of parts because of wear or damage, that each part must be
completely interchangeable with each other similar part, and that the items expected to function
without part replacement strict interchangeability could be uneconomical.
The guidelines below are useful to achieving maximum interchangeability of parts and units in a
given system:
1. Ensure that when physical interchangeability is a design characteristic, there is also
functional interchangeability.
2. When functional interchangeability is not desirable, there is no need for physical
interchangeability.
3. Avoid differences in size, shape, mounting, and other such characteristics.
4. All parts/units/components expected to be identical should be completely interchangeable
and identified as interchangeable.
5. Provide sufficient information in job instructions and on plate identification for users to
decide with a certain level of confidence if two like items are interchangeable.
6. Provide adapters to make physical interchangeability possible in situations where
complete (i.e., both functional and physical) interchangeability is not possible.
7. Ensure that part /unit modifications do not change the method of mounting and
connecting.

STANDARDIZATION
Standardization may be described as the attainment of maximum practical uniformity in an item’s

design. Although standardization should be a central goal of design because use of nonstandard
parts can result in lower reliability and increased maintenance, it must not be permitted to interfere
with advances in technology or improvements in design.
The advantages of standardization include:
1. Reduction in design time, manufacturing cost, and maintenance time and cost
2. Eliminates the need for special or close tolerance parts of components
3. Useful to reduce errors in wiring and installation caused by variations in characteristics of
similar items or units
4. Useful to reduce the probability of accidents stemming from incorrect or unclear procedures
5. Reduction in wrong use of parts or components
6. Useful to facilitate “cannibalizing” maintenance approaches
7. Improvement in reliability
8. Reduction in procurement, stocking, and training problems