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Reliability Engineering

R. Goswami

Meaning of Reliability
Scooter

A- No Check Ups, 1
unpredictable Break-Down every 6
months
Scooter B- Regular Check Ups every
month. No Break-Downs.

Availability
In normal circumstances, reliability of an
asset or machine or system is related to
how much time it is available for use, cost
of making it available etc, etc

Definition of Availability or
Availability Function or
Availability Performance

The ability of equipment to function


properly, despite occurrence of failures,
disturbances and limitations in the
maintenance resources.

3 Parts of Availability
Performance
Reliability

Performance

Maintenance

Support Performance

Maintainability

Performance

Reliability Performance
Defined

as The ability of an item to


perform a required function under stated
conditions of use for a stated period of
time
Measured by MTTFMean Time To
failure.

Maintenance Support
Performance
Defined

as The ability of a maintenance


organization to provide the required resources
to maintain an equipment under stated
condition
Measured by MWTMean Waiting Time.

Maintainability Performance
Defined

as The ability of an equipment to be


retained or restored in a state in which it can
perform a required function, when
maintenance is performed using stated
procedures & resources.
Measured by MTTRMean Time To Repair.

To Sum Up till Now--Availability


Performance

Reliability
Performance
---MTTF

Maintenance
Support
Performance
---MWT

Maintainability
Performance
---MTTR

Availability Targets for coaches,


wagons and Locos
Coach- Availability Target = 90%

Ineffective10% (Inside W/s 6.5%; Marked for W/s1%;


Sick2.5%).

Wagons- Availability Target = 96%


Ineffective 4%

Locos -Availability Target = 90% Ineffective


10%

Availability and Maintenance


Availability

Is

is a function of maintenance

maintenance a necessary evil ?

What

is the objective of maintenance ?

Maintenance
To

repair damaged equipment or To keep


equipment in operation?
Is reducing maintenance cost the sole
objective ?
Availability performance costs money but less
availability or unpredicted non-availability
costs even more money!
Therefore,-----

Maintenance

Maintenance is profitable !
A Good Maintenance strategy built
on Availability performance will
save money in the long run.

Definition of Maintenance
The term Maintenance covers all
activities undertaken to keep equipment
in a particular condition or to return it to
such condition.

Objective of Maintenance
To keep up planned availability
performance, equipment effectiveness
and technical lifetime at lowest possible
cost within safety prescriptions

3 Main parts of Maintenance


Maintenance

Corrective
Maintenance

Preventive
Maintenance

Improvement
Maintenance

Corrective Maintenance
Covers

all Maintenance which are carried out


to correct (repair) a fault in equipment.

May

be planned or unplanned

Corrective Maintenance

Unplanned
Break Downs
Emergency Repairs
Urgent
Not possible to
control
You are controlled
by the equipment

Planned
Planned
Maintenance
Prepared Properly
Possible to control
You control the
equipment

Preventive Maintenance
Covers

all programmed/scheduled
Maintenance which is carried out in order
to prevent the occurrence of failures or
to detect failures before they develop to
a break down or interruptions in
production.
2 types.

Preventive Maintenance
Indirect

Condition based
maintenance (CBM)
Detection of failures
before break down.

Direct

Fixed time
maintenance (FTM)
Cleaning, lubrication,
fixed time
replacement.

Indirect Preventive Maintenance


Subjective CBM

Done by senses.
Person/ experience
dependent
Should be
discouraged

Objective CBM

Measured by
instruments
continuous condition
monitoring is costly

Improvement maintenance
To

reduce recurring failures by detailed


failure analysis.

Failures
Random
Regular

Conclusion1
What

should be the best maintenance


strategy?
Best maintenance strategy depends on
cost.
Its a judicious mix of all types of
maintenance at least cost.

Conclusion2
Basic Maintenance Cycle
Planning
Performance

Analysis
Recording

Last slide

Thank You !