MG 443: Tutorial 1

1. Basic Maintenance 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) Define the following terms
i. Inspection
ii. Job report
iii. Maintainability
iv. Maintenance schedule
v. Maintenance strategy
vi. Overhaul

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)

Answer:
Assuming negative exponential distribution, the system mean life or the mean time between
failures (MTBF) is given by:

1
MTBF 


i= 1 / MTBF
i.e., 1 = 0.000286 failure/hour
2 = 0.0002 failure/hour
3 = 0.000435 failure/hour
4 = 0.000625 failure/hour
5 = 0.000313 failure/hour
6 = 0.00025 failure/hour

a) For series system R = e- (i)x 2000 = 0.0147

b) For parallel system R = 1-[(1-R1) (1-R2) (1-R3) (1-R4) (1-R5) (1-R6)]
R = 1-[(1-e-0.000286)(1-e-0.0002)(1-e-0,000435)(1-e-0.000625)(1-e-0.000313)(1-e-0.00025)
R=0.9999

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?

Answer:
Let x = be the event that a breakdown is not repairable
a) then P(x) = P(A).P(x/A)+P(B).P(x/B)+P(C).P(x/C)+P(D).P(x/D)+P(E).P(X/E)
Therefore P(x) = 0.15*0.04+0.25*0.06+0.20*0.02+0.18*0.08+0.22*0.10
P(x) = 0.0614

b) P(B) = P(B).P(x/B)/P(x)
P(B) = 0.25*0.06/0.0614
P(B) = 0.244

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 3.

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

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
Cumulative 12 26 36 44 50 56 60 64 68 70
Failure
Cumulative
Percent

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

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 R10 R11 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.

Solution
MTBF = 100 =>  = 1/100 = 0.01

Using Poison method t =40 hours without failure, n=1,

nt = 1x0.01x50 = 0.5
From poison chart the probability of no failure for 50 hours at r=0, nt = 0.5 we get 0.6

The second method is by using negative exponential function

 
R(t) = e 
t
- t
= e-t
R(50) = exp(-50x0.01) = exp(-0.5) = 0.606
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?

Solution
In this case r = 3, t = 40 hours, n = 10  = 0.01

nt = 10x0.01x40 = 4
From the Poisson chart for r = 3 and nt = 4 we get probability of 3 failures to be 0.4

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?

Solution:
a) When connected in series R(50) = exp(-0.01x50x4) = 0.135
n
b) When connected in parallel R(50) = R(t) = 1 - (1 - R)
R(50) = 1 – (1-0.606)4
= 0.976

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