Tutorial 3

Question 1.
a) What do you understand by the term median active corrective maintenance time?
b) Use the data given on table 1 to calculate:
i. Median active corrective maintenance,
ii. Median active preventive maintenance, and
iii. Maximum active corrective maintenance at 95% confidence level from the following
information (For this sample Z at 95% = 1.65).
Maintenance actions 3,5,8,11 are preventive maintenance actions and the remaining are
breakdown maintenance actions

Table 1: List of maintenance times

Maintenance action Total downtime [Minutes] Logistics Delay time Administrative delay time
[Minutes] [Minutes]
1 148 45 67
2 167 34 44
3 150 68 42
4 132 26 46
5 180 44 66
6 143 23 36
7 243 56 74
8 112 22 30
9 67 12 22
10 120 46 24
11 280 78 42
12 187 45 55

Question 2
i) What do you understand by the term maximum active corrective maintenance time (Mmax)?
ii) Calculate Mmax at 95% confidence level from the data shown on table 1 and table 2
iii) Use the data depicted on table 1 and intellectual assumption to calculate the following data if given that
the cycle time was 24,000 minutes:
a) Total Availability A; b) Inherent Availability A1; c) Achieved availability Aa;
d) Operational Availability Ao.
Table 1: Downtime of some selected maintenance activities. Activities number 3, 7, 9 and 14 are break down
maintenance whereas the rest of activities are preventive maintenance.
Maintenance Activity No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Td 3 4 2 3 4 6 4 2 3 4 6 8 8 10
[Hours]
LDT 75 120 40 45 100 160 98 44 45 90 155 200 230 320
[Min.]
ADT 65 45 25 35 80 140 102 26 35 90 145 160 159 160
[Min.]
Td is the total downtime that includes both the LDT and ADT.

Table 2: Risks/Upper limit variations

Risk Confidence Z Upper limit [min.]
5% 95% 1.65 65.72
10% 90% 1.28 64.89
15% 85% 1.04 64.35
20% 80% 0.84 63.89
Answer:
Question 1:
a) The median maintenance time is that value which divides all of the downtime values so that 50%
are equal to or less than the median and 50% are equal to or greater than the median. The
median will usually give the best average location of the data sample (2 marks)

i) Mdct is calculated as:

n

  log Mct  i

Mdct  anti log i 1

n
Corrective maintenance actions are 1,2,4,6,7,9,10,12
Maintenance Total Logistics Administrative Active Log Mctii
action downtime Delay time delay time Corrective
[Minutes] [Minutes] [Minutes] Maintenance
Time Mcti
1 148 45 67 36 1.56
2 167 34 44 89 1.95
4 132 26 46 60 1.78
6 143 23 36 84 1.92
7 243 56 74 113 2.05
9 67 12 22 33 1.52
10 120 46 24 50 1.70
12 187 45 55 87 1.94
 552 14.42

Mdct = antilog (14.42/8) = antilog (1.8025) = 63.46 Minutes

ii) Mdpt is calculated similarly as Mdct and it is given mathematically as:

  fpt  log Mpt 

n

M pt  anti log
d
i i
or   log Mpt  i

 fpt i Mdpt  anti log i 1

n

Preventive maintenance action include 3,5,8, and 11

Maintenance Total Logistics Administrative Mpti Log Mpti
action downtime Delay time delay time [Minutes]
[Minutes] [Minutes]
3 150 68 42 40 1.60
5 180 44 66 70 1.85
8 112 22 30 60 1.78
11 280 78 42 160 2.20
 330 7.43

Therefore Mdpt = antilog (7.43/4) = antilog (1.8575) = 72.03 Minutes

iii) Maximum active corrective Maintenance time is given by:

  ____________ 
M max  anti log  log Mct  Z log Mcti 
 
Z is given as 1.65,

2
N 
   logMCti 
N
  logMCti 2   i1 N 
i 1
 logMCti
N 1

and
N

  log Mct  i
log MCti  i 1
N

Maintenance Total Logistics Administrative Active Log Mctii (log Mcti)2

action downtime Delay time delay time Corrective
[Minutes] [Minutes] [Minutes] Maintenance
Time Mcti

1 148 45 67 36 1.56 2.42

2 167 34 44 89 1.95 3.80
4 132 26 46 60 1.78 3.16
6 143 23 36 84 1.92 3.70
7 243 56 74 113 2.05 4.22
9 67 12 22 33 1.52 2.31
10 120 46 24 50 1.70 2.89
12 187 45 55 87 1.94 3.76
552 14.42 26.26

 log MCti 14.42

 log MCti  i 1
  1.80
N 8

26.26 
14.42 2
 log MCti  8
7
 0.196

 M max  ant log1.80  1.65 *  0.196 

 132.9 Minutes
Question 2

i) What do you understand by the term maximum active corrective maintenance

time (Mmax)?

Answer:
Mmax can be defined as that value of maintenance downtime below which a specified
percent of all maintenance actions can be expected to be completed.

ii) Calculate Mmax at 95% confidence level from the data shown on table 1 and
table 2

Answer:

M max  anti log log MCti  Z log MCti 
At 95% confidence level Z = 1.65

2
N 
   logMCti 
N
**   logMCti 2   i1 N 
i 1
 logMCti
N 1

Tdown LDT ADT MCti Log (MCti) (Log(MCti)2

120 40 25 55 1.74 3.03
240 98 102 40 1.60 2.67
180 45 35 100 2.00 4.00
600 320 160 120 2.08 4.32
 7.42 14.02

  log Mct  i
7.42
 log MCti  i 1
  1.86
N 4

7.422
14.02 
 log MCti  4
3
 0.29

 M max  ant log1.86  1.65 *  0.29  

 218.02 Minutes
iii) Use the data depicted on table 1 and intellectual assumption to calculate the
following data if given that the cycle time was 24,000 minutes:
b) Total Availability A;
c) Inherent Availability A1;
d) Achieved availability Aa;
e) Operational Availability Ao.

Table 1: Downtime of some selected maintenance activities. Activities number 3, 7, 9

and 14 are break down maintenance whereas the rest of activities are
preventive maintenance.
Maintenance Activity No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Td 3 4 2 3 4 6 4 2 3 4 6 8 8 10
[Hours]
LDT 75 120 40 45 100 160 98 44 45 90 155 200 230 320
[Min.]
ADT 65 45 25 35 80 140 102 26 35 90 145 160 159 160
[Min.]
Td is the total downtime that includes both the LDT and ADT.

Table 2: Risks/Upper limit variations

Risk Confidence Z Upper limit [min.]
5% 95% 1.65 65.72
10% 90% 1.28 64.89
15% 85% 1.04 64.35
20% 80% 0.84 63.89

Answer:
i) Total Availability is given by the following relationship
A = 1- Td/Ttotal
Total downtime Td = 67 hours

Total available time = Cycle time = 400 hours

Therefore A = 1 – 67/400 =0.832

ii) Inherent Availability Ai is given by

MTBF
Ai 
MTBF  MCt

From the information given there are 4 failures in a cycle time of 400 hours

4
 Failure rate  
400
 1 400 x60
MTBF    6,000 min
 4

MCt excludesLD
T andADT

MCt3 = 120 – (40+.25) = 55

MCt7 = 240 – (98+102) = 40
MCt9 = 180 – (45+35) = 100
MCt14 = 600 – (320+160) = 120

 MCt 55  40  100  120

 MCt  i 1
  78.75
n 4

6000
Ai   0.987
6000  78.75

iii) Achieved Availability Aa is given by:

MTBM
Aa 
MTBM M
MTBM Mean
Where TimeBetween
Maintenance
.
 includes
bothpreventive
and 
 
 corrective
maintenance
actions


From the information given there are 14 maintenance actions within the 400 hours
400 x 60
 MTBM   1714.29 min
14

Mµ = average time to perform scheduled and unscheduled maintenance actions

It excludes ADT and LDT

MCti have already been calculated

MPt1 = 180 –(75+65) = 40

MPt2 = 240 –(120+45) = 75
MPt4 = 180 –(45+35) = 100
MPt5 = 240 –(100+80) = 60
MPt6 = 360 –(160+140) = 60
MPt8 = 120 –(44+26) = 50
MPt10 =240 –(90+90) = 60
MPt11 = 360 –(155+145) = 60
MPt12 = 480 –(200+160) = 120
MPt13 = 480 –(230+159) = 91

40  75  55  100  60  60  40  50  100  60  60  120  91  120

 M   73.64 min
14

1714.29
 Aa   0.96
1714.29  73.64

iv) Operational Availability Ao is given by:

MTTF
Ao 
MTTF MTTR MWT

MTTF  MTBF
 6,000 min

MTTR  MCt
 78.75 min

MWT  Mean Waiting Time

 Total LDT and ADT 
  
 14  Actions  

2989
  213.50 min
14
6000
Ao 
6000  78.75  213.50

= 0.953