IE 443: Tutorial 1

1. Introduction to Maintenance and Terminology

a) Mention 4 activities of Maintenance work planning

b) Mention 4 activities of Maintenance programming
c) Mention 4 activities of Maintenance Controlling
d) What is the difference between availability factor and utilization factor?
e) Compare “Check” and “Test” with respect to maintenance terminology
f) Compare the terminology availability factor and utilization factor?
g) Compare Job card and work order
h) Compare work requisition and Job specification
i) Explain importance of ‘record keeping’ and ‘machine history card’ in maintenance
activity.
j) Explain the use of PERT chart for shutdown maintenance activity with suitable
example.
k) What is online maintenance?
l) What do you understand by the term “Maintenance Controlling AND What are the
main activities of Maintenance Controlling?
m) Mention 4 main known objectives of maintenance
n) Compare the term “Operational availability and Reliability”
o) Mention the six functions (or types) of maintenance analysis
p) Mention 3 maintenance induced factors in a facility that affect the quality of the
production process?
q) Define the following terms
i. Inspection
ii. Job report
iii. Maintainability
iv. Maintenance schedule
v. Maintenance strategy
vi. Overhaul
r) Elaborate different Organization structures and their positioning of the maintenance
activities, and its effect in the implementation of maintenance programs.

2. Failure Analysis

i) A system has six main components whose MTBF are 3500 hours, 5000 hours, 2300
hours, 1600 hours, 3200 hours and 4000 hours. Calculate the resulting reliability at
2000 hours of the system if the components were connected a) in series and b) in
parallel. (Assume negative exponential distribution is applicable in this case)
ii) MJ Enterprise has five departments: A, B, C, D, and E. The enterprise has been
collecting maintenance data for a long period. According to the data, it is shown that
department A produces 15% of all failures in the company whereas departments B, C,
D, and E produces 25%, 20%, 18% and 22% respectively. Further, it was found that
some of the failures are repairable whereas some are irreparable. According to the
data the irreparable breakdowns in departments A, B, C, D and E are 4%, 6%, 2%,
8% and 10% respectively
 a) What is the probability that a random breakdown that has occurred in MJ
enterprise will be irreparable?
b) What is the probability that a random breakdown that has found irreparable
occurred in department B?
iii) Discuss the basic four characteristics of a Weibull distribution under different values
of 
iv) Use the Weibull log-log paper distributed and the data shown on table 1 to calculate
the instantaneous failure rate at t=1000 hours of a piece of equipment, whose data is
shown on Table 1.

Table 1: Weibull Data for Equipment characteristics

Age at 300 400 500 600 700 800 900 1000 1100 1200
failure
[hours]
Number of 12 14 10 8 6 6 4 4 2 2
failure

v) Comment on the age of the equipment whose data are shown on table 3
vi) What do you understand by the term attrition failure?
vii) What do you understand by the term instantaneous failure rate?
viii) Weibull distribution function and negative exponential function are among the highly
used distribution functions in failure analysis. At what juncture is Weibull distribution
function equals to the negative exponential function?
ix) Derive the formula to calculate the instantaneous failure rate from the first principle
using Weibull distribution function, and use the formula to calculate the instantaneous
failure rate of a system at 1000 hours after a replacement using the following available
data:
 = 2.2,  = 10;  = 100
x) What is the basic (or main) reason of carrying out failure analysis?
xi) Briefly explain the following human errors that causes failure to occur: Errors of
knowledge, Errors of performance, Errors of intent
xii) Briefly discuss any 3 most common root cause analysis methods
xiii) Using examples contrast primary cause and root cause

3. Reliability Analysis

a) Reliability and Network Analysis

i) Discuss the 4 (four) elements that describe the reliability function
ii) Why do we say the reliability is an intrinsic characteristic of a piece of equipment?
ii) Calculate the reliability of the system shown on figure 1 using the following given data:

R1 R2 R3 R4 R5 R6 R7 R8

0.45 0.55 0.68 0.35 0.50 0.70 0.8 0.60

R9 R10 R11

0.44 0.68 0.75

 R5
R9
R1
R6

input R2 R4 R7 R 10 R 11 output

R3 R8

Figure 1: Reliability testing of RS 00056.

b)
i) Determine the probability that a system will operate for 50 hours without failure if it
is known that the system has a mean life of 100 hours.
ii) If the system in i) is installed in 10 different equipment what is the probability that 7
such equipment will operate without failure for 40 hours?
iii) If 4 of the system in i) are connected in a) series, b) parallel, what will be the resulting
reliability of the system at t=50?

c) Use the figure below and calculate the reliability of the system if all of the shown
maintenance action were failure based maintenance actions