OVERVIEW OF RELIABILITY

ENGINEERING AND MAINTAINABILITY

FOR A MORE EFFECTIVE SYSTEM

Baron, Rosendo J.
EE 181: Maintainability Engineering
EE181 YZ

May 31, 3021

 TABLE OF CONTENTS

TABLE OF CONTENTS
I. INTRODUCTION .......................................................................................................................3
II. OBJECTIVES 3
III. RELIABILITY ENGINEERING .......................................................................................................4
Reliability ....................................................................................................................................4
Reliability Theory ........................................................................................................................4
Bathtub Hazard Rate Curve .........................................................................................................6
Failure Intensity Rate ..................................................................................................................7
Mean-Time-to-Failure (MTTF) .....................................................................................................8
Mean Life (Θ) ..............................................................................................................................8
Mean-Time-Between-Failures (MTBF) .........................................................................................8
Reliability of a System and its Components .................................................................................9
IV. MATHEMATICAL MODELS OF MAINTAINABILITY ...................................................................11
Required Spare Part Quantity Estimation ..................................................................................11
Annual Mean Maintenance Labor-Hours Estimation ..................................................................11
Fault Detection Probability Estimation ......................................................................................12
Mean Time to Detect Estimation ...............................................................................................13
V. REFERENCES ..........................................................................................................................14
 I. INTRODUCTION

In an age of technology advances, process industry has been at the center of the development
of projects that have been the foundation of the economy’s growth, but as the economy flourished,
the downside of these projects were the problems encountered during the forecasting of the projects’
profitability using maintaining budgeted costs to suffice its performance (Stapelberg, 2009).Hence,
Reliability Engineering and Maintainability Engineering of these systems are used to address this
problem wherein Reliability is the probability of a product or an equipment to properly function
without any occurrence of failure given its stated condition in a specific period (Dhillon, B.S., 1999).
Reliability Engineering is interdisciplinary field of study that focuses on the performance of systems
and its components during a specific time with conditions that deemed the system to operate.
Moreover, it also includes the design analysis, planning, and warranty and maintenance (Jin, 2018).
On the other hand, Maintainability Engineering are the measures taken to be able to meet the
requirements of the products and to maximize its use while reducing the cost used during its
development, design, and installation stages while considering its maintenance requirements while
also incorporating maintenance engineering analyses (Dhillon, 1999).

II. OBJECTIVES

The general objective of the study is to evaluate the learnings of the student through the
topics discussed.

Specifically, this study aims to:

1. discuss what is Reliability Engineering, its concepts, and principles; and

2. determine and discuss the mathematical models of Maintainability.

 III. RELIABILITY ENGINEERING

In this section, concepts and principles of Reliability Engineering will be discussed to further
understand its purpose and problems encountered. Analysis in Reliability Engineering is used to
determine the effectiveness of a system and its components to make ways on upgrading its capability
on its operation (Stapelberg, 2009).

Reliability

According to Jin (2018), Reliability is the probability of a system, and its parts, of availability
and failure which is applied in a particular period. It is restricted to the stated conditions during its
operation and the product is assumed to fail eventually. Dhillon (1999) discussed the purpose of
reliability which is to decrease the occurrence of failures, improving the simplicity of the system, and
the standardization of its components while considering human factors and safety issues that could
affect the performance of the system and its components.

As the advancement of systems has been increasing, reliability has been a main focus since
the systems tends to be more sophisticated and complex and the limited budget for investments in
the operation and maintenance of redundant systems which have back-ups that has been evident
and these problems result for the systems to be unreliable. Hence, failures would be more probably
to occur over the given specified time (Stapelberg, 2009). Failure is the system and its components’
inability to function given the stated condition on the given period of time (Dhillon, 1999).

Reliability Theory

Essentially, the nature of engineering is mathematics. The theories behind Reliability,

Availability, and Maintainability are mathematical procedures and statistics. Moreover, the concept
of reliability will be more understandable using discrete and continuous random variables, density
functions, and distribution functions and use these to predict a system’s failure (MIL-HDBK-338B,
1998). The cumulative distribution function F(t) is the probability of a random trial in a random variable
is not greater than t which is denoted in Equation 3-1 (MIL-HBDK-338B, 1998).

𝑡
𝐹(𝑡) = ∫ 𝑓(𝑡)𝑑𝑡
−∞
(Equation 3-1)
where:

F(t) is the unreliability function

f(t) is the probability function of a random variable, time to failure

Definitely, the reliability function or the probability of an equipment to not fail is denoted in
Equation 3-2(MIL-HDBK-338B) below. Moreover, the probability of failure can be expressed by the
reliability function in a time interval t1 and t2 is denoted in Equation 3-3 (MIL-HDBK-338B, 1998).

∞
𝑅(𝑡) = 1 − 𝐹(𝑡) = ∫ 𝑓(𝑡)𝑑𝑡
𝑡

(Equation 3-2)
where:

R(t) is the reliability function

Differentiating Equation 3-2, f(t) can be expressed as Equation 3-3 which is shown below

dR(t)
= 𝑓(𝑡)
dt

(Equation 3-3)

Equation 3-2 which is the reliability function can be expressed in terms of time interval
between t1 and t2.

∞ ∞
∫ 𝑓(𝑡)𝑑𝑡 − ∫ 𝑓(𝑡)𝑑𝑡 = 𝑅(𝑡1) − 𝑅(𝑡2)
𝑡1 𝑡2

(Equation 3-4)
 Failure Rate, λ(t), is the ratio of probability that failure occurs in the time interval t1 and t2
and the interval length of the failure is denoted in Equation 3-5 (MIL-HDBK-338B, 1998).Moreover,
Jin (2018) added that failure rate is the frequency of a system of component to fail which is
expressed per unit time.
𝑅(𝑡1)−𝑅(𝑡2) 𝑅(𝑡)−𝑅(𝑡+𝛥𝑡)
𝜆(𝑡)= =
((𝑡1)−(𝑡2))𝑅(𝑡1) 𝛥𝑡𝑅(𝑡)

(Equation 3-5)

where:
t is t1

t+Δt is t 2

Hazard Rate, h(t), is the limit of the failure rate as the interval length approaches zero.
Furthermore, it is the change in survivor rate per unit change in in terms of time (MIL-HDBK-338B,
1998). Moreover, hazard rate is the time where the first failure occurs (Jin, 2018).

𝑙𝑖𝑚𝛥𝑡→0𝑅(𝑡)−𝑅(𝑡+𝛥𝑡) −1𝑑𝑅(𝑡) 1−𝑑𝑅(𝑡)

ℎ(𝑡)= = = 1𝑅(𝑡)
𝛥𝑡𝑅(𝑡) 𝑅(𝑡)𝑑𝑡 𝑅(𝑡)𝑑𝑡

𝑓(𝑡)
h(𝑡)=
𝑅(𝑡)

(Equation 3-6)

Jin (2018) related that failure rate and hazard rate are applied to non-repairable systems but
can also be used for repairable systems given that its components are non-repairable. Moreover, it
always has a value of non-negative.
Bathtub Hazard Rate Curve

Bathtub Hazard Rate Curve or Failure Rate Curve is a representation of a system or component’s
failure with respect to its lifetime. It is most commonly used for electronic equipment and systems. The
curve shows an approximate of a system or equipment’s failure with corresponding characteristics from
infant mortality as it approaches wear out period. The curve is divided into three parts: (1) Infant
Mortality, (2) Useful Life, and (3) Wear out. Infant Mortality or Zone I is characterized by having a high
number of failures as the system ages, but there is a decreasing failure rate (DFR). This stage most
commonly occurred when the system or equipment is first introduced until its manufacturing process,
which is a result from poor design, poor manufacturing methods, substandard components and
materials were used to build the system or the lack of initial control in the system. Failures during this
stage can be lessen and eliminated by burn in, which is a period where the equipment is used and the
stress experienced is equal to the condition where the equipment is intendedly used. Useful Life or
Zone II is the stage where it experiences constant failure rate (CFR). These failures just occur randomly
and can be eliminated by good preventive maintenance actions. Some of the reasons for these failures
to occur are low safety factors, undetectable defects, abuse, higher random stress than expected,
unavoidable conditions, and human errors. Lastly, wear out or Zone III occurs as the system experiences
an increasing rate failure (IRF). It results from the degradation of the system or equipment due to its
age (Jin, 2018). It can also result from wrong overhaul processes, and short designed-in life of the
product. In Figure 3-1 shows the Bathtub Hazard Curve is presented

Figure3-1. Bathtub Hazard Rate Curve

Source: Jin, T., 2018

 Failure Intensity Rate

Failure Intensity Rate which is denoted by m(t) and is defined by the ratio of accumulative
failures which result to repair and its operation time. Also, referred to the rate of the reoccurring
failure (ROCOF) in the system. It is also known as the repair time of a system or equipment which is
shown in Equation 3-7(Jin, 2018).

𝑀(𝑡)
m(𝑡)=
𝑡

(Equation 3-7)

where:

M(t) is the repairs

t is the operation time of the system

Mean-Time-to-Failure (MTTF)

Mean Time to Failure (MTTF) is the expected lifetime of a system or component before it
fails (Jin, 2018). It is derived from basic statistical theory and L’Hopital’s Rule is used to expressed
MTTR in Equation 3-8 (MIL-HDBK-338B, 1998).

∞
MTTF = ∫ 𝑅(𝑡)𝑑𝑡
0

(Equation 3-8)
 Mean Life (Θ)

Mean Life (Θ) is the measure of the item’s total population being considered. Essentially, it is
the arithmetic mean time to fail of the population which is presented in Equation 3-9 (MIL-HDBK-338B,
1998).
𝑛
1
θ = ∑ 𝑡𝑖
𝑛
𝑖=1

(Equation 3-9)

where:

𝑡𝑖 is the time to failure of the ith of the population.

n is the total number of items of the population

Mean-Time-Between-Failures (MTBF)

Mean-Time-Between-Failures (MTBF) is the measure of average time in the occurrence of two

consecutive failures in the operating time of a system or (Jin, 2018). MTBF is used for repairable
systems and is expressed in Equation 3-10(MIL-HDBK-338B, 1998).

𝑇(𝑡)
MTBF=
𝑟

(Equation 3-10)
where:
T(t) is the operating time
R is the number of occurred failures

Reliability of a System and its Components

The advancement of systems to be more complex and sophisticated posed a problem the
unreliability of the system and its components. These advancements also causes a limit in the budget
for the maintenance and operating cost for the system. Hence, it became more important for
practices to be utilized to make the systems more reliable. System is defined as the whole set with
different components that work together with their own mechanisms for the system to be efficiently
working. On the other hand, components are the parts or elements that creates the whole system and
has their own function in it.
 Reliability of systems and its components can be analyzed using models to further understand
its nature. Components in a system can be connected either in series or parallel. Systems with
components that are connected in series should all function properly and must work together for the
system to be essentially working. The reliability of systems which are connected in series is governed
by the Law of Multiplication which states “if two or more independent events, the probability that all
events will occur is given by the product of the respective probabilities.” (Stapelberg, 2009).
Reliability of series configuration is shown in Equation 3-11 and
represented in Figure 3-2.

𝑅𝑠𝑦𝑠𝑡𝑒𝑚 = ∏𝑛𝑖=1 𝑅𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑖

(Equation 3-11)

Figure 3-2. Series Configuration of a System

Source: MIL-HDBK-338B, 1998

The reliability of a system in parallel configuration can be described as a redundant system which
requires only at least one component to work and the others as back-up to say the system is working
as a whole. The system reliability of parallel configuration is greater than the reliability of its
components. It follows the General Law of Addition which states “if two events occur simultaneously,
the probability that either one or more will occur is given by the sum of the individual probabilities of
occurrences less than the product of the individual probabilities.” (Stapelberg, 2009). The system
reliability of parallel configuration is shown in Equation 3-12 (Stapelberg, 2009) and represented in
Figure 3-3.

𝑛 𝑛

𝑅𝑠𝑦𝑠𝑡𝑒𝑚 = ∑ 𝑅𝑖 − ∏ 𝑅𝑖

𝑖=1 𝑖=1

(Equation 3-12)
Figure 3-3. System Reliability of a Parallel Configuration
Source: MIL-HDBK-338B, 1998
 IV. MATHEMATICAL MODELS OF MAINTAINABILITY

The increasing demand for advancement leads to higher cost on the operation and support of
systems and equipment. Therefore, it is vital to create measures that will help in reducing the required
maintenance, manhours, tools used in the operation without compromising the requirements and
quality of products (Dhillon, 1999). In this chapter, mathematical models of maintainability were
discussed in which are used in addressing the reoccurring problems that are hindrance to the effective
operation of systems and its components.

Required Spare Part Quantity Estimation

The estimation of the quantity of spare is important because it is safe to have a certainty
that there will be an available spare when needed. The quantity is highly based on the reliability of the
system and its components on whether it would be replaced by a spare (Dhillon, 1999).
Furthermore, spare part support activities which are based from the consumption of spare parts
which is important in determining if there is enough quantity of spare parts, if it is of good quality and,
has a high reliability when used. Spare part support activities include financing, storage, supply and,
management works (Zhu, 2017). The Required Spare Part Quantity Estimation is based on Poisson
Distribution and is shown in Equation 4-1(Dhillon, 1999).

𝑒−𝑛λt
𝑆𝑃 = ∑𝑚
𝑖=0((−1) ln(𝑒
−𝑛λt 𝑖
))
𝑖!

(Equation 4-1)

where:
SP is the probability of having a spare of a specific partavailable
n is the number of spares of a specific type used
t is the time
λ is the constant failure rate of a spare of a specific type m is the number of spare parts
carried in stock
 Annual Mean Maintenance Labor-Hours Estimation

Annual Mean Maintenance Labor-Hours Estimation is the total average of preventive and corrective
maintenance labor hours done in a span of one year (Dhillon, 1999). As the system complexity
increases and the demand for higher standards in maintenance increases, one factor to consider of
having an effective maintenance is the decision making on determining the type of personnel for a
specific maintenance work and estimating the size of the workload to determine the number of
personnel to work (Ran et al, 2018). Knowing the Mean-Time-to-Repair (MTTR) and Mean-Time-
Between-Failures (MTBF) is important to determine the estimation for the annual mean maintenance
labor-hours which is shown in Equation 4-2 (Dhillon, 1999).

𝑇𝑠(𝑀𝑇𝑇𝑅)(𝑁𝑐)
𝑀𝐿𝐻𝑎= + 𝑇𝑝𝑚(𝑁𝑝)
𝑀𝑇𝐵𝐹

(Equation 4-2)

where:

MLHa is the mean maintenance labor-hours per year

Ts is the number of operating hours per year
MTBF is the Mean-Time-Between-Failures
MTTR is the Mean-Time-To-Repair
Nc is the mean number of persons required to perform a corrective maintenance task
Tpmis the mean preventive maintenance time
Np is the mean number of persons required to perform a preventive maintenance task

Fault Detection Probability Estimation

Fault Detection Probability Estimation is a measure of the equipment’s fault detection

accuracy in order to determine its availability (Dhillon, 1999). The early detection of faults will help to
estimate the useful life of the system and its components to stop or at least slow down the progression
of faults to maintain the reliability of the system and its components. Moreover, there are a number
of false alarms included in early detection, therefore, a reliable fault detector must be used (Zhang et
al, 2011). The equation for Fault Detection Probability Estimation is shown in Equation 4-3 (Dhillon,
1999).
 (∑𝑘
𝑖=1 𝜃𝑗 𝜆𝑑𝑗
𝑃𝐷𝑐𝑓= ∑𝑛
𝑖=1 𝜆𝑗

(Equation 4-3)

where:

n is the total number of items

k is the total number of items possessing some degree of fault detectability

λj is the failure rate in item j
λdj is the detectable failure rate of item j
θj is the portion of the failure rate that is detectable for item j
𝑃𝐷𝑐𝑓 is the probability of detecting faults correctly

Mean Time to Detect Estimation

Determining the Mean Time to Detect is important in order to know the suitability of an
effective operation to the item which has not been used and cannot be monitored. It is also defined
as the time between the failure and the test (Dhillon, 1999). Mean Time to Detect Estimation is shown
in Equation 4-4 (Dhillon, 1999).

𝑇 1
𝑀𝑇𝑇𝐷= −
(1−𝑒 −𝜆𝐼 𝑇 ) −𝜆𝐼

(Equation 4-4)

where:

MTTD is the mean time to detect

T is the test period
λI is the item failure rate
 V. REFERENCES

DHILLON, B.S. (1999). Engineering Maintainability: How to design for reliability and easy maintenance.
[Electronic Version]. Houston, Texas: Gulf Publishing Company

JIN, T. (2019). Reliability engineering and services. [Electronic Version]. Hoboken, New Jersey: John
Wiley & Sons Inc.

MIL-HDBK-338B. (1998). Military handbook: electronic reliability design handbook. [Electronic

Version].

QIAN, Z., SHENYANG, L., ZHIJIE, H., & CHEN, Z. (2017). Prediction model of spare parts consumption
based on engineering analysis method. Procedia Engineering, 174, 711–716. doi:
10.1016/j.proeng.2017.01.210

RAN, Q., WANG, Q., & SUN, Z. (2018). Maintenance man-hours calculation model based on the age
replacement. IOP Conference Series: Earth and Environmental Science, 170, 032021.
doi:10.1088/1755-1315/170/3/032021

STAPELBERG, R.F. (2009). Handbook of reliability, availability, maintainability, and safety in

engineering design. [Electronic Version].

ZHANG, B., SCONYERS, C., BYINGTON, C., PATRICK, R., ORCHARD, M. E., & VACHTSEVANOS, G.

(2011). A probabilistic fault detection approach: application to bearing fault detection. IEEE
Transactions on Industrial Electronics, 58(5), 2011–2018. doi:10.1109/tie.2010.2058072