IE 443/MG 443: Tutorial 1

1. Introduction to Maintenance and Terminology

a) Mention 4 activities of Maintenance work planning
✓ maintenance strategy planning
✓ maintenance personnel planning
✓ planning of maintenance equipment
✓ maintenance materials planning
✓ maintenance budgeting
✓ maintenance consultation.
b) Mention 4 activities of Maintenance programming
✓ planning of maintenance programmes
✓ maintenance capacity planning
✓ planning for maintenance schedules
✓ quantity planning

c) Mention 4 activities of Maintenance Controlling

✓ scrutinises the availability of the equipment,
✓ harmonises the distribution of the maintenance tasks,
✓ monitors the available capacity and
✓ collects the data concerning the work orders

d) What is the difference between availability factor and utilization factor?

Availability factor is the ratio of Availability to the period of maximum requirement
While
Utilization factor is the ratio of Availability to the period of actual use

e) Compare “Check” and “Test” with respect to maintenance terminology

Both involves comparison with an acceptable standard by suitable or defined means.

But
In “Check” whilst the facility is non-operational and in “Test” whilst the facility is
operational.
f) Compare the terminology availability factor and utilization factor?
Both involves the ratio of availability with the period.

g) Compare Job card and work order

Job card is a document requesting the maintenance work to be done
while
Work order is a written instruction detailing work to be carried out

h) Compare work requisition and Job specification

Work requisition is a document requesting work to be carried out
while
Job specification is a document describing the maintenance work to be done

i) What do you understand by the term “Maintenance Controlling AND What are the main
activities of Maintenance Controlling?
◼ Maintenance controlling deals with the releasing and monitoring of the maintenance
work orders.
◼ Main activities of maintenance controlling:
a) Scrutinises the availability of the equipment.
b) Harmonises the distribution of the maintenance tasks.
c) Monitors the available capacity.
d) Collects the data concerning the work orders.

j) Mention 4 main known objectives of maintenance

◼ quality of products
◼ economical aspects
◼ organisational aspects
◼ safety matters
k) Compare the term “Operational availability and Reliability”
Operational availability is the probability that a piece of equipment, when used in actual
operational environment under specified conditions will operate (i.e. do its job) satisfactorily
when called upon
Reliability is the probability that a component, device or system will perform its prescribed
duty without failure for a given time when operated correctly in a specified environment.

l) Mention the six functions (or types) of maintenance analysis

It deals with
◼ Weak points analysis.
◼ Root cause analysis.
◼ Availability analysis.
◼ Maintainability analysis.
◼ Reliability analysis.
◼ Deviations analysis.
m) Mention 3 maintenance induced factors in a facility that affect the quality of the
production process?
◼ Economy.
◼ Safety.
◼ Environment.

n) Define the following terms

i. Inspection
Inspection refers to "actions for substantiating and assessing the real-condition of the
technical system” or
It is the process of ensuring by assessment that a facility reaches the necessary standard
of quality or performance and that the level is maintained

ii. Job report

Job report is a statement recording the work done and the condition of the facility

iii. Maintainability
Maintainability can be defined as the inherent characteristic of a design or installation
that determines the ease, economy, safety, and accuracy with which maintenance
actions can be performed

iv. Maintenance schedule

 Maintenance schedule is a comprehensive list of maintenance tasks and their
incidence

v. Maintenance strategy
Maintenance strategy is the principal function of planning, whereby the type of
maintenance, the extent of doing and the time of carrying out of maintenance actions
will be established

vi. Overhaul
Overhaul is a comprehensive examination and restoration of a facility, or a major part
thereof to an acceptable standard

2. Failure Analysis
i) A system has four main components whose MTBF are 3000 hours, 2000 hours, 1200
hours, and 1800 hours. Calculate the resulting reliability at 1000 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)
−𝑇
Reliability = P(no failure before T) = 𝑒 𝑀𝑇𝐵𝑇
Given T = 1000hrs,
Consider the table below;
1 −𝑇 −𝑇
S/N MTBF in hrs. λ = 𝑀𝑇𝐵𝐹 𝑒 𝑀𝑇𝐵𝑇
𝑀𝑇𝐵𝐹
(in 10−3 )
1 3000 0.3333 0.3333 0.7165
2 2000 0.5 0.5 0.6065
3 1200 0.8333 0.8333 0.4346
4 1800 0.5556 0.5556 0.5738
∑ λ = 2.2222

a. When components are connected in series

= 0.7165 × 0.6065 × 0.4346 × 0.5738
∴ 𝑹𝒆𝒍𝒊𝒂𝒃𝒊𝒍𝒊𝒕𝒚 = 𝟎. 𝟏𝟎𝟖𝟑𝟕
 b. When they are connected in parallel
𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = 0.7165 + [0.6065 × 0.2835] + [0.4346 × 0.3935 ×
0.2835] + [0.5738 × 0.5654 × 0.3935 × 0.2835]
Reliability = 0.7165 + 0.1719 + 0.0485 + 0.03619
∴ 𝑹𝒆𝒍𝒊𝒂𝒃𝒊𝒍𝒊𝒕𝒚 = 𝟎. 𝟗𝟕𝟑𝟎𝟗
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 
◼  < 1: F(t) decreases as t increases. This is the case of decreasing failure rate
with time
◼  = 1 in this case the Weibull equation is reduced into a negative exponential
DF. This shows a constant local failure rate.
◼ 1<  < 2, gives a skewed distribution function, which show a rapid decrease of
F’(t) as t approaches 0. This represents an increase in the failure rate with
time.
◼  > 2 the distribution becomes more symmetrical as the values of B increases.
◼ At  = 3.2 the Weibull distribution function is approximately equal to the
Normal distribution function.

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
failures

iv) 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?

◼ IFR of equipment at time t is the probability that the equipment will fail in the next
time interval given that it is working at the start of the interval.

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?
◼ When  = 1 in this case the Weibull equation is reduced into a -ve exponential DF.

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
Solution:
the probability that the equipment will fail in the interval from 0 to t, F(t) is given as,
t

F (t ) =  f (t )dt
0

The average rate of failure in the period [t, t + t) is the conditional probability that the
equipment will fail in the period [t, t + t], given that the equipment is running at time t
divided by t.
𝐹(𝑡 + 𝛥𝑡) − 𝐹(𝑡) 1
𝑍(𝑡) = 𝛥𝑡 → 0 .
𝛥𝑡 𝑅(𝑡)
 Hence the instantaneous failure rate Z(t), is obtained by taking the limit of the above
expression for average failure rate as t approaches zero
d
F(t)
dt f(t) f(t)
Z(t) = = =
R(t) R(t) 1 - F(t)

x) What is the basic (or main) reason of carrying out failure analysis?
◼ Failure rate analysis is a statistical property of an equipment.
◼ It is used in equipment replacement studies.
◼ It is used to estimate correct maintenance actions and resources.

xi) Briefly explain the following human errors that causes failure to occur: Errors of
knowledge, Errors of performance, Errors of intent
◼ Error of knowledge: This may cause the application of wrong material to design a
component that may cause a failure.
◼ Errors of performance: these are consequences of lack of sufficient care or of
negligence. Negligence can make someone to misread drawings, to give inadequate
specifications, or to produce defective manufacturing and poor workmanship.
◼ Error of intent: it involves greed. Greed leads to actions usually carried out with a
conscious or unconscious denial of full knowledge of the potential consequences.

xii) Briefly discuss any 3 most common root cause analysis methods
◼ Events and causal factor analysis: used to identify the time sequence of series of tasks
and/ or action and the surrounding conditions leading to occurrence.
◼ Change analysis: used when the problem is obscure or unclear.
◼ Barrier analysis: used to identify physical, administrative and procedural barriers or
control that should have prevented the occurrence.
xiii) Using examples contrast primary cause and root cause
◼ The poor finish, the incorrect heat treatment, the shape of the screw threads, etc., are
the “primary causes’ of those failures, not the root causes
◼ The root causes would be:
✓ the failure to check the finish after machining,
 ✓ the failure to check the finish after machining,
✓ the failure to ensure that the heat treatment furnace had sufficient control of
changes in temperature to produce the desired microstructure in the rails, or
✓ The failure to enter the proper information into the thread-cutting process; etc
3. Reliability Analysis
a) Reliability and Network Analysis
i) Discuss the 4 (four) elements that describe the reliability function
◼ Probability indicates that reliability says something about the ratio of actual operating
time to the specified period of operation.
◼ Satisfactory performance refers to the meeting of certain criteria considered as
acceptable performance by management
◼ Time must be known in order to arrive at the probability that a given equipment
functions as programmed.
◼ Specified operating conditions, are the environmental standards such as temperature
and humidity.
ii) Why do we say the reliability is an intrinsic characteristic of a piece of equipment?
◼ Reliability is an intrinsic characteristic of the design of a system; it must be planned,
determined, and specified as part of the overall planning of the system.
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.

∴ 𝑹𝒆𝒍𝒊𝒂𝒃𝒊𝒍𝒊𝒕𝒚 = 𝟎. 𝟑𝟒𝟑𝟖𝟐
c) 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.
∴ 𝑹𝒆𝒍𝒊𝒂𝒃𝒊𝒍𝒊𝒕𝒚 = 𝟎. 𝟔𝟎𝟔𝟓
i) 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?
ii) 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?