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EDMF15 - Diploma of Mechanical Engineering
15FMCE214 – Preventive Maintenance Techniques
Assignment 1/ Continuous assessment
Written Exam
Online Turnitin submission
Monday 21 December 2020- Thursday 24 December 2020
P3M1, P3M2, P3M3
Eng. Meryem, Eng. Shiva
 All questions must be answered correctly in order to meet
assessment requirements. Please use black or blue pen, not pencil

DO NOT WRITE IN THE AREA BELOW

Question Number Maximum Marks Student Marks
1 2
2 2
3 4
4 7

Total Mark 15

Assessor Feedback:
15FMCE214 : Preventive Maintenance Techniques Assessment 2

Note: The weight of this assignment is 15%. Your answer should be written in this
document and submitted to MYLMS. Only PDF format of your typed work will be
considered.

The deadline for submission will be Thursday 24 December 2020 at 4 PM. Please note that
the time and date will not be extended.

Question 1: (2 marks)

Give a brief interpretation of the following curve.

Figure1. Maintenance Cost

Interpolation of the curve:-

From the curve we can see that:

1) The curve shown above represents the difference in amount of total cost which is basically
depending upon two maintenance activities that are “preventive maintenance” and
“corrective maintenance”.
2) There is linear relationship between “preventive maintenance cost” and “amount of
maintenance activity” if one increases other increases as well whereas there is inverse
relationship between “corrective maintenance cost” and “amount of maintenance
activity” if one increases the other decreases and vice versa.
3)We know that corrective maintenance is performed after the failure of any equipment or
machine occurs and preventive maintenance is performed before failure occurs just to
prevent the chances of failure.

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15FMCE214 : Preventive Maintenance Techniques Assessment 2

4) In order to achieve best cost of maintenance which is too high neither too low it necessary
to perform optimum preventive and corrective maintenance.
5) From graph we can see that if excessive preventive maintenance is performed total cost
increases and if preventive maintenance is performed after due time then total cost also
decreases but at the same time corrective maintenance cost increases.
6) Area of optimal maintenance zone lies in between preventive maintenance and corrective
maintenance which is conjunction of both activities in this region the total cost of
maintenance is minimum.
7) From the graph total maintenance cost initially decreases to a minimum point and the
starts increasing gradually this is because if preventive maintenance is performed at first
the total cost will be high but if corrective maintenance is performed before preventive
maintenance there will be no preventive maintenance cost and overall cost will be less.

Question 2: (2 marks)

Working equipment details has been recorded for 24 hours as shown in the graph below.
Give the Mean Time between Failures for this equipment.

Failure
Downtime cause: Effective
inadequate speed Operation
Effective Failure
Effective Effective
Operation
Operation Operation

Solution:

Operational Hours = (24 – 1 – 0.5 – 1) =21.5 hours

Now,

Mean Time between Failure =

Mean Time between Failure = = 10.75 hours/failure

Mean Time between Failure = 10.75 hours/failure

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15FMCE214 : Preventive Maintenance Techniques Assessment 2

Question 3: (4 marks)

During the diagnosis of Pacemaker failures, a medical company gave the following records:
-1000 heart pacemakers tested
-5000 hours of testing
-50 pacemakers failed halfway through testing

Calculate:
1- The percent of failures?
2- The number of failures per unit hour?
3- The number of failures per unit year?
4- The expected time to repair and place a Pacemaker, is 6 hours. Calculate the time to failure
5- If 22000 people receive units, how many expected to fail in following year?

Data Given from Question:

Number of units tested [No] = 1000

Hours of testing per unit [t] = 5000
Number of units failed in test [Nf] = 50

Solution:
(1) The percentage of failures = * 100

The percentage of failures = * 100

The Percentage of Failures = 5%

(2) The number of failures per unit hour =

The number of failures per unit hour = *

The Number of Failures per Unit Hour = 10 * 10-6 per hour

OR
The Number of Failures per Unit Hour = 0.000010 per hour
(3) The number of failures per unit year = Number of failure per unit hour * 8760 ∵ 365 * 24 = 8760

The number of failures per unit year = 10 * 10-6 * 8760

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15FMCE214 : Preventive Maintenance Techniques Assessment 2

The Number of Failures per Unit Year = 0.0876 per year

(4) Time to failure = 10 * 10-6 * 5000 hours testing time

t = 10 * 10-6 * 5000
t = 0.05 hours
(5) For a batch of 22000 units
Calculating number of failures for a year
Number of failure = Failure rate * Batch size
Number of failure = 0.0876 * 22000
Number of Failure = 1927.20 units

1927 units are expected to fail following year.

Question 4: (7 marks)

A servicing equipment used in SERVISCO company is composed of four subsystems is shown

in diagram below. Knowing that:

- The reliability of the subsystem A is 0.75

- The reliability of the subsystem B is 0.81
- The reliability of the subsystem C is 0.67
- The reliability of the subsystem A is 0.98

1- Calculate the reliability of this system.

During testing period, 10 servicing equipment have been evaluated. The record of
breakdowns is presented in the table below:

Number of 0 2 3 5 6
breakdowns
Frequency of 0.1 0.5 0.2 0.4 0.1
occurrence

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15FMCE214 : Preventive Maintenance Techniques Assessment 2

The average cost of breakdown is 70KD. In order to improve the reliability, SERVISCO
company decides to contract out the preventive maintenance to MSC company. The
contract will include fixed fees of 100 KD and the cost of:
 Spare parts: 5KD
 Labor: 50KD
 Consumables: 10KD
 Equipment: 5 KD
MSC company performed a trial period in which 10 servicing equipment have been
controlled, the record of breakdown presented by this company is shown by the table
below:

Number of 0 1 2 4
breakdowns
Frequency of 0.7 0.3 0.1 0.05
occurrence

2- If SERVISCO expect a 30 % reduction of total annualized maintenance cost (AMC), is it

better to contract the preventive maintenance service to MSC?

3- To sign the contract, SERVISCO require a minimum 50% reliability improvement. MSC
suggests duplicating only two subsystems which represent the lower reliability. Only one
similar redundant component will be considered for each subsystem. Will SERVISCO
sign the contract with MSC? If yes, calculate the annualised maintenance cost.

Solution:
(1) Reliability of subsystem A = 0.75
Reliability of subsystem B = 0.81
Reliability of subsystem C = 0.67
Reliability of subsystem D = 0.98
Reliability of the system in series is given by formula:
R = R1 * R2 * R3 * R4
R = 0.75 * 0.81 * 0.67 * 0.98
Reliability = R = 0.3988845
OR
Reliability = R = 39.8 %
Reliability of the system = 39.8 % (approximately)

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15FMCE214 : Preventive Maintenance Techniques Assessment 2

From this we can conclude that, the decision of SERVISCO Company to contract out the
preventive maintenance to MSC Company is good option.

(2) Yes, if SERVISCO expect a 30 % reduction of total annualized maintenance cost (AMC), is
it better to contract the preventive maintenance service to MSC.
(3) Yes SERVISCO will sign contract with MSC
Cost Analysis:
Number of Breakdown Frequency of Occurrence
0 0.1
2 0.5
3 0.2
5 0.4
6 0.1

Expected number of breakdowns = ∑ (Number of breakdown) * (Frequency)

Expected number of breakdowns = (0)(0.1) + (2)(0.5) + (3)(0.2) + (5)(0.4) + (6)(0.1)
Expected Number of Breakdowns = 4.2
Expected breakdown cost = (Expected number of breakdown) * (Cost per breakdown)
Expected breakdown cost = (4.2) * (70)
Expected Breakdown Cost = 294 KD/month
Preventive maintenance cost = Cost of expected breakdown + Cost of service contract

Preventive maintenance cost = (1 breakdown per month * 70) + (100 KD)

Preventive Maintenance Cost = 170 KD/month

So, preventive maintenance results in saving 124 KD/month

It is concluded we should hire MSC, it is less expensive.

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