Introduction to Maintenance and Reliability Engineering
Development and Definition
o Probability-success of the mission of the product
o Intended Function-Why we actually bought the product
o Satisfactory-acceptable degree of compliance
o Specific period of time-the light limit of the product
o Specified Conditions- pressure, speed or any state or condition to perform its action
Maintenance, Failure and Time actually associated but also reliability engineer can be used to defined
reliability
Reliability
ability of an item to perform a required function under given conditions for a given time interval
(IEC 60050)
The probability that an item will perform a required function without failure under stated
condition for a stated period of time (Smith, D.J. 2005)
Can be defined as the probability that an item/system will perform a required function without
failure under stated conditions for a stated period of time
Can also be expressed as the number of failures over a period.
A time dependent characteristic.
o It can be only be determined after an elapsed time but can be predicted at any time
o It is the probability that a product or service will operate properly for a specified period
of time (design life) under the design operating conditions without failure
Development of Maintenance and Reliability Engineering
o First Generation Maintenance (Pre-WW2)
o Industry not highly mechanized so downtime not particularly important
o Most Equipment simple and over-designed
Reliable and easy to repair
Eventually just wore out
o Only Systematic maintenance required -simply cleaning, servicing and lubrication.
o Philosophy: Fix it when it Breaks
o Second Generation Maintenance (WW2 to mid-70’s)
o More mechanization and concern over downtime-trying to do a plan
o Idea that failures could and should be prevented – they are doing prevented
maintenance
o Awareness of burn-in failure mode-testing it until it breaks
Bath-tub curve- relationship between time and failure it breaks
o Increase in maintenance costs as a proportion of total operating costs-preparing the
tools and the spare parts.
Development of first planning and scheduling tools
o Philosophy: Preventative Overhauls
o Third Generation Maintenance (Mid-70’s+)
o Aircraft data identifies 6 different failure mod patterns
o Growth of mechanization and automation increases focus on plant availability and
reliability
o Effects of failures on HS&E becomes important as regulations tighten
HS&E stands for Health Safety and Environment
o Cost of maintenance increases: Often 1 st or 2nd highest of all operating costs.
o New techniques become available to collect data that would enable maintainers to
Predict failures-Predictive Maintenance
Optimize maintenance decisions- Asset Management
How Reliability is Measured?
Objectives of Reliability Engineering
To apply engineering knowledge and specialist techniques to prevent or reduce the likelihood or
frequency to failure.
To identify and correct the causes of failures that do occur, despite of the efforts to prevent
them
To determine ways of coping with failures that do occur, if their causes have not been corrected
To apply method for estimating the likely reliability of new designs, and for analyzing reliability
data
Theory and Basic Concepts
Role of a Mechanic and Engineer
To understand more about the reliability engineering, it is important to differentiate or
describe the roles of different department working in the industry.
Role of a Mechanic
Makes routing inspections, documents inspections and repairs
Performs scheduled maintenance-routine inspection
Run tests after making repairs of performing maintenance
Job duties may vary based on which part of the plane is being worked on. A mechanic
working on the exterior of a plane may be fixing a broken wing, repairing paint or securing a door
so it seals properly. A mechanic working on the engine may be changing the oil, replacing belts or
repairing a broken part.
An A&P (Airframe and Power plant) mechanic must know and follow all regulations set
by the FAA. FAA regulations govern the maintenance schedules, inspections and repairs made to
airplanes. The FAA conducts regular checks on equipment and ensures regulations are being met.
Role of an Engineer (Design)
To develop new technological solutions
o Includes defining problems
o Conducting and narrowing research
o Analyzing criteria
o Finding and analyzing solutions and making decisions
Role of an Engineer (Analysis)
Engineers apply techniques of engineering analysis in testing, production, or
maintenance.
Supervise production in factories and elsewhere.
Determine the causes of a process failure
Test output to maintain quality
Estimate the time and cost required to complete projects
Maintenance
The most misunderstood about maintenance is the true objective of the function. The
objective of maintenance is to maintain the assets of a company so that they meet the reliability need at
an optimal cost.
In webster’s Dictionary maintenance means to maintain, keep in existing condition,
preserve, protect and keep from failure or decline
The ultimate goal of maintenance is to provide optimal reliability which meets the
business need of the company.
Types of Maintenance
Breakdown Maintenance (Reactive)
o It means that people waits until equipment fails and repair it. Such a thing could be used
when the equipment failure does not significantly affect the operation or production or
generate any significant loss other than repair cost.
Preventive Maintenance (Proactive) (No Occurrences of Failure)
o It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain
the healthy condition of equipment and prevent failure through the prevention of
deterioration, periodic inspection or equipment condition diagnosis, to measure
deterioration. Just like human life is extended by preventive medicine, the equipment
service life can be prolonged by doing preventive maintenance.
Periodic Maintenance (Time Based Maintenance, Scheduled Maintenance)
Time based maintenance consists of periodically inspecting, servicing
and cleaning equipment and replacing parts to prevent sudden failure
and process problems
Predictive Maintenance
This is a method in which the service life of important part is predicted
based on inspection or diagnosis, in order to use the parts to the limit of
their service life. Compared to periodic maintenance, predictive
maintenance is condition-based maintenance. It manages trend values,
by measuring and analyzing data about deterioration and employs a
surveillance system, design to monitor condition through an on-line
system.
Corrective Maintenance (Intensive way of taking good care of the product) (Almost in the
breakdown maintenance but in a sense of Preventive Maintenance) (E.G. Wear out on the
wirings, Dents, Cracks)
o It improves equipment and its components so that preventive maintenance can be
carried out reliably. Equipment with design weakness must be redesigned to improve
reliability or improving maintainability.
Maintenance Prevention (Creating a new Version or Upgrade) (Wanting to improve the
weaknesses)
o It indicates the design of a new equipment. Weakness of current machines are
sufficiently studied (on site information leading to failure prevention, easier
maintenance and prevents of defects, safety and ease of manufacturing) and are
incorporated before commissioning a new equipment.
Zero Hours Maintenance (Overhaul) (Carried out Preventive Maintenance, you cannot do
overhaul without scheduling) (Resetting the Time, Putting it as a new as possible) (requirement
at least once a year)
o
