01 Reliability and Availability Intro

8/10/2019 01 Reliability and Availability Intro

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MSc Maintenance Management

MMH131155

Reliability and Availability Assessment

Senior Lecturer: Dr Babakalli Alkali

2014

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Module Leadrer

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TITL

E

NAME

Dr Babakalli AlkaliRoom: C013Phone: 0141 331 357!mail: babakalli"alkali#$cal"ac"uk
mailto:[email protected]:[email protected]


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!M Al"ali

#Sc$ MSc$ %&'$ M(RS$ MIMA$ )HEA*Senior Lecturer in t&e 'e+artment Engineering

Sc&ool o, Engineering and uilt Environment$ -lasgo. /aledonian 0niversity$/o.caddens Road$ -lasgo. - 2A

%&one 411 331 3567$ )a8 411 331 3792

Emailbaba"alli!al"ali:gcu!ac!u"

'r aba"alli is t&e AHo' o, 'e+artment o, Mec&anical Engineering$ and t&e module leader ,or maintenancemanagement$ reliability and availability and T(-I module at -lasgo. /aledonian 0niversity! Tutor ,or t&e EnergyAudit and Energy Asset Management module!

'r aba"alli .as a Researc& )ello. at Strat&clyde 0niversity$ 'e+artment o, management science$ Strat&clydeusiness Sc&ool$ -lasgo. #;225 ;22


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Module SummaryThis module aims to provide an understanding of the

fundamentals of reliability and decision theory. It will

examine these techniques as applied to risk, reliability,

availability and maintenance management. It will also

bridge the gap between theoretical subject of "Reliability

Engineering" RE! and daytoday equipment maintenance

practice. In addition# techniques will be treated to analyse

field data to report on business targets. $part from thesequantitative approaches# attention will be paid to a variety

of formal# qualitative ris% identification and maintenance

optimisationmethods used in industry.

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(n com+letion o, t&is module$ you

s&ould be able to

%&e the conce't& o( 'robabilit) an* &tocha&tic *eci&ion& theor) to

+uantitati,el) anal)&e a -'ro*uction. &)&tem /"r"t" the ri&k& o( not meetin$

&a(et) an*or en,ironmental tar$et&"

uantitati,e a&&e&&ment o( 'ro*uction ca'acit) -'robabilit) reliabilit) an*maintenance characteri&tic&"

%&in$ thi& theoretical in&i$ht an* en$ineerin$ ,ie/& em'lo) techni+ue& to

+uanti() the e((ect& o( ,ariou& maintenance an* in&'ection &trate$ie&

man'o/er an* acti,it) 'lannin$&che*ulin$ &trate$ie& (or &'are 'art& lo$i&tic&"

%&e (iel* *ata to anal)&e the im'act o( im'lemente* maintenance &trate$ie& onthe com'an) bu&ine&& 'lan"

%n*er&tan* the &tren$th an* limitation& o( +uantitati,e RA techni+ue& an*

com'are the&e /ith +ualitati,enormati,e metho*& u&e* in in*u&tr)"

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Teac&ing Mode

Lecture&

utorial&

Ca&e Stu*ie&

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Assessment rie,s

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STARTCEED

EN'CEED

T%E 'ES/RI%TI(N H(0RS CEI-HIN-

4 7 /ourse.or" Reliability Analysis /C1 #;5F*$

Ris" Analysis /C; #;5F*

17 52F

14 15 E8ams Ans.er Any 3 out o, 7 Guestions ; &ours 52F

Please note the following statement on plagiarism:- 'The deliberate andsubstantial unacknowledged incorporation in your submission of material

derived from work (published or unpublished of another is prohibited. !n

such cases the work submitted is classified as illegal and will result in

further action being taken by the "niversity which may include recording a

failure.'

A&&e&&ment etho*

Cour&e/ork 50

!6am& 50


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G0ESTI(NS

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ac"groundhe reco$nition o( reliability and maintainability a&

,ital (actor& in the *e,elo'ment 'ro*uction an*

maintenance o( to*a)>& com+le8 systems ha& 'lace*$reater em'ha&i& on the a''lication o( *e&i$n e,aluation

techni+ue& to lo$i&tic mana$ement" Reliability an*

maintainabilitycan i*enti() critical ,ailure modes an*

cau&e& o( (ailure an* 'ro,i*e an e((ecti,e tool (or're*ictin$ e+ui'ment beha,iour an* &electin$

a++ro+riate mea&ure& to en&ure satis,actory

+er,ormance

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IntroductionReliabilit) ha& al/a)& been an im'ortant a&'ect in the

a&&e&&ment o( in*u&trial 'ro*uct& an*or e+ui'ment&"

?oo* 'ro*uct *e&i$n i& o( cour&e e&&ential (or 'ro*uct& /ith

hi$h reliabilit)"


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Reliability Engineering he &tu*) o( reliability engineering i& ba&e*

on the im'ro,ement anal)&i& a&&e&&ment

an* 're*iction o( 'er(ormance o( e+ui'ment

an* &)&tem&

an) reliabilit) anal)&i& re+uire the u&e o(

&tati&tical techni+ue& to ai* in the anal)&i&

an* 're*iction o( 'er(ormance o( &)&tem&13


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History o, Reliability he notion o( +uantitati,e anal)&i& o( reliabilit) i&

*ate* back to the 1@40>&

he nee* (or mo*ern technolo$) in the &'ace 'ro$ram

le* to +uantitati,e a''roach ba&e* on mathematical

mo*ellin$ an* anal)&i&

hi& $a,e im'etu& to the ra'i* *e,elo'ment o(

reliabilit) theor) an* metho*olo$ie& in the 1@50>&

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Reliability History A more +uantitati,e a''roach to reliabilit) $re/ in *eman* an*

'articularl) out o( the e6'erience& in the 9orl* 9ar /ith com'le6

&)&tem& Barlo/ an* Pro&chan -1@5."

Barlo/ -1@4. 'ro,i*e a hi&torical 'er&'ecti,e o( mathematical

reliabilit) en$ineerin$ in electronic e+ui'ment in &'ace reliabilit)

technolo$)

he 50thAnni,er&ar) S'ecial Publication o( the !!! ran&action on

Reliabilit) -Eol 47 =o 3FSP Se't" 1@@. contain& &e,eral hi&torical

'a'er& *ealin$ /ith ,ariou& a&'ect& o( reliabilit) a''lication&

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/urrent Reliability %rediction Reliabilit) 're*iction& i& 'er(orme* in the earl) &ta$e

o( a *e,elo'ment 'ro$ramme -*e&i$n &ta$e.

he a/arene&& o( 'otential *e$ra*ation o( e+ui'ment

*urin$ li(e c)cle

he 'er(ormance o( reliabilit) 're*iction (or electronic

&)&tem& i& /ell e&tabli&he* b) RGD (or e6am'le LF


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Reliability %rediction Met&ods Reliabilit) 're*iction i& ba&e* on *atabank in(ormation an* a

/i*e *i&'er&ion o( (ailure rate& /hich occur (or &imilar

com'onent&

Stan*ar*i&ation an* the ma&& 'ro*uction o( electronic 'art&

ha& 'ermitte* the creation o( ,ali* (ailure rate& (or hi$h

'o'ulation electronic *e,ice&

ualit) in(ormation can be u&e* *irectl) to 're*ict o'erational

reliabilit) /hile *e&i$n i& &till on the *ra/in$ boar*

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Inconsistencies in ,ailure rates

#mec&anical e=ui+ment* n*i,i*ual mechanical com'onent& &uch a& ,al,e& an* $earbo6

'er(orm more than one (unction an* (ailure *ata (or &'eci(ic

a''lication& o( non&tan*ar* com'onent are &el*om a,ailable

Hailure rate& o( mechanical com'onent are not *e&cribe* b)con&tant (ailure rate becau&e o( (ati$ue *e$ra*ation an* other

&tre&&Frelate* (ailure mechani&m

echanical e+ui'ment reliabilit) i& more &en&iti,e to loa*in$

o'eratin$ con*ition than electronic e+ui'ment he *e(inition o( (ailure o( mechanical e+ui'ment *e'en*&

u'on it& a''lication -e"$ e6ce&& noi&e or leaka$e.

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C&y are de,inition im+ortantDe(inition& an* &tan*ar*& in reliabilit) en$ineerin$ are o( $reat &i$ni(icance *ue to

the (ollo/in$ rea&on&:

he) are /ritten b) authoritie& in the (iel*I 'ractitioner& an* aca*emic& /ho are$uru& in the (iel*"

he) are there(ore /ritten ,er) care(ull) &o that it i& *i((icult to &/a' an) /or* in

the *e(inition /ith an alternati,e one"

he) &tan* time" De(inition& la&t (or $eneration&"

he) in(luence culture&" Hor e6am'le (ailure in the 9e&t i& *e(ine* a& Jterminationo( (unctionK /herea& the ;a'ane&e treat it a& *eterioration o( (unctionK an* hence

the &i6 lo&&e&" hi& ha& in(luence* our *e&i$n o( CS in ca'turin$ (ailure"

he) hel' to &tan*ar*i&e the lan$ua$e -(or e6am'le (or contract& an* (or recor*in$

(ailure&."

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C&at is Reliability

ne o( the +ualit) characteri&tic& that

con&umer& re+uire (rom the manu(acturer

o( 'ro*uct& i& reliabilit)" But /hat i& reliabilit)

M he abilit) (or an e+ui'ment to 'er(orm& it&

(unction /hen re+uire* -e"$ &tartin$ )our car." m'ortance o( reliabilit):

M !6am'le& o( (ailure an* &ucce&& ca&e&"

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Reliability

he reliabilit) o( an item in u&e $enerall) *eteriorate /ith a$e"

hi& *eterioration coul* be a((ecte* b) &e,eral (actor&

inclu*in$ en,ironment o'eratin$ con*ition& an* maintenance

Deterioration can be &lo/e* b) increa&in$ maintenance but at

increa&in$ co&t&

=ote that the reliabilit) o( a 'ro*uct ,arie& o,er it li(ec)cle

an* a thorou$h reliabilit) anal)&i& ma) be nece&&ar) at man)

&ta$e&

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'e,inition o, Reliability

JReliability is the probability that a product or service will

operate properly for a specified period of time design life!

under the design operating conditions such as temperatureor volt! without failure.& Elsayed# '(()!

n other /or*& reliabilit) ma) be *e(ine* a& a mea&ure o(

the &)&tem>& &ucce&& in 'ro,i*in$ it& (unction 'ro'erl)"

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Selected 'e,inition

Reliabilit): NNNNNNNNNNN""

Re*un*anc): NNNNNNNNNNN"" Hailure: NNNNNNNNNNN""

aintainabilit):NNNNNNNNNNN

A,ailabilit):NNNNNNNNNNN""

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Selected 'e,inition

Reliability he abilit) o( an item to 'er(orm a re+uire* (unction un*er &tate*

con*ition& (or a &tate* 'erio* o( time -BS 477."

Redundancyhe e6i&tence o( more than one mean& o( accom'li&hin$ a $i,en

(unction" !ach mean& o( accom'li&hin$ the (unction nee* not nece&&aril) be i*entical-LFSDF721B."

)ailurehe termination o( the abilit) o( an item to 'er(orm a re+uire* (unction -BS

477."

Maintainabilityhe abilit) o( an item un*er &tate* con*ition& o( u&e to be retaine*

in or re&tore* to a &tate in /hich it can 'er(orm it& re+uire* (unction& /hen

maintenance i& 'er(orme* un*er &tate* con*ition& an* u&in$ 're&cribe* 'roce*ure& an*

re&ource& -BS 477."

Availabilityhe abilit) o( an item -un*er combine* a&'ect& o( it& reliabilit)

maintainabilit) an* maintenance &u''ort. to 'er(orm it& re+uire* (unction at a &tate*

in&tant o( time or o,er a &tate* 'erio* o( time -BS 477."

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Maintenance Terminology

tem relate* term&

Pro'ertie& o( item&

Hailure& an* e,ent&

Hault& an* &tate&

aintenance t)'e& an* &trate$ie&

aintenance acti,itie&

ime relate* term&

aintenance &u''ort an* tool& !conomical an* technical in*icator&

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asic terms

aintenance

m'ro,ement

o*i(ication

Hailure

Hault

A,ailabilit)

Reliabilit)

aintainabilit)

Su''ortabilit)

Pre,enti,e aintenance

Correcti,e aintenance

Pre*etermine* aintenance

Con*ition Ba&e* aintenance

mme*iate Correcti,e aintenance

De(erre* Correcti,e aintenance

Co&t !((icienc)

Pro*ucti,it)

A&&et ana$ement

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aintenance Combination o( all technical a*mini&trati,e an* mana$erial

action& *urin$ the li(ec)cle o( an item inten*e* to retain in itor re&tore it to a &tate it can 'er(orm the re+uire* (unction

m'ro,ement

Combination o( all technical a*mini&trati,e an* mana$erialaction& inten*e* to ameliorate the *e'en*enc) o( an item

/ithout chan$in$ it& re+uire* (unction

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o*i(ication Combination o( all technical a*mini&trati,e an* mana$erial

action& inten*e* to chan$e the (unction o( an item

=ote: mo*i(ication *oe& not mean re'lacement b) an e+ui,alent

item

=ote: o*i(ication& i& not a maintenance action but ha& to *o /ith

chan$in$ the re+uire* (unction o( an item to a ne/ (unction" he

chan$e& ma) ha,e an in(luence on the *e'en*abilit) or the'er(ormance o( item or both

=ote: o*i(ication ma) be allocate* to the maintenance

or$ani&ation

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Hailure ermination o( the abilit) o( an item to 'er(orm a re+uire* (unction

=ote 1: A(ter a (ailure the item ha& a (ault /hich ma) be com'lete or

'artial"

=ote 2: JHailureK i& an e,ent a& *i&tin$ui&he* (rom J(ault&K /hich i&

a &tate"

Hault State o( an item characteri&e* b) inabilit) to 'er(orm a re+uire*

(unction e6ten*in$ the inabilit) *urin$ 're,enti,e maintenance or

other 'lanne* action& or *ue to lack o( e6ternal re&ource&

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Summary T&e 'e,inition o,

Reliability

Reliabilit) *etermine& to /hat *e$ree a &)&tem&)&tem&

are able to achie,e the inten*e* (unction'er(ormance

in &'ite o( error& *i&turbance& an* limite* maintenance

re&ource&

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A122F

T&e variable used

,or measuring

reliability is

availability


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Availability

Availability *e'en*& on reliability and maintainability

o 're*ict &)&tem& a,ailabilit) both (ailure an* re'air'robabilit) *i&tribution mu&t be con&i*ere*" 9e /ith the

$eneral ob&er,ation the

otal u'time an* *o/ntime /ill 'ro,i*e the 'ercenta$e

time the &)&tem i& a,ailable" he main intere&t i& to 're*ict

the a,ailabilit)

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Do/ntime%'time

%'timet)A,ailabili

+

=


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Relations&i+ bet.een t&e /(N/E%TS

o, RELIAILIT

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In,luence t&e tec&nical

system t&e mac&ine or

+lant

In,luence t&e maintenance

system


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Availability

%er,ormance

Reliability Maintainability

T&e tec&nical system

Maintenance

Su++ortability

T&e maintenance system


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o, RELIAILIT

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Availability time ,or +roduction

Mean

'o.ntime

MT) MCT MTTR

Mean time bt! ,ailure

Mean

Caiting

Time

Mean

Time To

Re+air


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o, RELIAILIT

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Sel*om

a *o/n &tate

o( the item

Sim'le an* (a&t

aintenance

acti,it)

he item i&a,ailable (or u&e

he ri$ht re&ource&

at the ri$ht 'lace

at the ri$ht time


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70

20

10

70

10

20

10

20

70

'esign

Pro*uction

Maintenance

MaJor

Moderate

Minor

C&at &as t&e biggest

in,luence u+on t&e result


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o, RELIAILIT

O MT)

Earie& *ue to:

Con*ition

monitorin$"

he *e&i$n"

Re*un*anc)" Choice o(

e+ui'ment or

com'onent&"

O MCT

Earie& *ue to:

r$ani&ation"

he in(ormation

&)&tem&"

Routine&" !*ucation"

rainin$"

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MTTR

Earie& *ue to:

Acce&&ibilit)" Built in te&t"

Hault in*ication"

Sta((>&

kno/le*$e" Sta((>&

moti,ation


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Availability +er,ormance he abilit) o( an item to be in a &tate to 'er(orm a re+uire* (unction un*er $i,en

con*ition& at a $i,en in&tant o( time or *urin$ a $i,en time inter,al a&&umin$ that

the re+uire* e6ternal re&ource& are 'ro,i*e*

=ote 1: hi& abilit) *e'en*& on the combine* a&'ect& o( the reliabilit) the

maintainabilit) an* the maintenance &u''ortabilit)

=ote 2: Re+uire* e6ternal re&ource& other than maintenance re&ource& *o not

a((ect the a,ailabilit) o( item

Reliability he abilit) o( an item to 'er(orm it& re+uire* (unction un*er a $i,en con*ition (or a

$i,en 'erio* o( time

=ote: he term reliabilit) i& al&o u&e* a& a mea&ure o( reliabilit) 'er(ormance an*

ma) al&o be *e(ine* a& 'robabilit)

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Maintainability Abilit) o( an item un*er a $i,en con*ition o( u&e to be re&tore* to a &tate in /hich

it can 'er(orm a re+uire* (unction /hen maintenance i& 'er(orme* un*er $i,en

con*ition& an* u&in$ &tate* 'roce*ure& an* re&ource&

=ote: the term Jmaintainabilit)K i& al&o u&e* a& a mea&ure o( maintainabilit)

'er(ormance

Maintenance Su++ortability

Abilit) o( a maintenance or$ani&ation o( ha,in$ the ri$ht maintenance &u''ort atthe nece&&ar) 'lace to 'er(orm the re+uire* maintenance acti,it) at a $i,en in&tant

o( time or *urin$ a $i,en inter,al

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MTTM

0+ state

'o.n state

MTC M

Total time interval

AoMTTM?#MTTM4MTC4M*

Ao (+erational availability MTCMean Time Caiting

MTTM Mean Time to Maintenance Time #+reventive and corrective*

MMean Maintenance Time #Time to +reventive and corrective maintenance*

Note In t&is calculation o, Ao$ only maintenance actions .&ic& cause sto++age

Time ,or t&e o+erational use o, t&e tec&nical system .ill be considered


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4242

Maintenance

%reventive Maintenance /orrective Maintenance

/ondition based

maintenance

%redetermined

maintenance

'e,erred ImmediateSc&eduledSc&eduled$

continuous or on

re=uest


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%reventive Maintenance #%M*

#aintenance carried out at predetermined intervals or according to prescribed criteria and

intended to reduce the probability of failure or the degradation of the functioning of an item.

O /ondition ased Maintenance #/M*

Preventive maintenance based upon performance and$or

parameter monitoring and the subse%uent actions.

&T: Performance and parameter monitoring may be scheduled, on re%uest or continuous.

O %redetermined Maintenance #%'M*

Preventive maintenance carried out in accordance with

established intervals of time or number of units of use but without previous condition

investigation.

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/orrective Maintenance #/M*

#aintenance carried out after fault recognition and intended to put an item into a state

in which it can perform a re%uired

function.

O 'e,erred Maintenance #'M*

)orrective maintenance which is not immediately carried out

after a fault detection but is delayed in accordance with given

maintenance rules.

O Immediate Maintenance #IM*

#aintenance which is carried out without delay after a fault has been detected to avoid

unacceptable conse%uences.

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Activities%reventive Maint

/orrective Maint

Reinvestment

/ost 'irect cost

Indirect cost

E8ternal cost

Results )e. ,unctional dist

)e. ,ailure

T&e state o, t&e

assets

/ost e,,iciency

RES0LTS?/(STS

E,,ect AAILAILIT

MIN 'IST0RAN/ES

G0ALIT

Resources 'irect &ours

Indirect &ours

0se o, tec&nical

resources

%roductivity

RES0LTS?0SE'

RES(0R/ES

Maintenance

'ecision /ost

E,,ective Strategy


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4

Rig&t

/a+acity

Rig&t

%roduction

Rig&t

Maintenance

Rig&t

Logistics

Logistics management

/om+any management designers

%roJect managers

%roduction

Management

Maintenance

Management


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Hor (urther in(ormation about aintenance

terminolo$)

See the !uro'ean Stan*ar*

C!= != 1330 aintenance erminolo$)

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Actions to im+rove reliability ,rom

design state

O )actors o, sa,ety!

M Lea*& to the com'oun*in$ o( man) *i((erent &a(et) (actor&"

M Com'en&ate (or uncertaint)"

M Lea* to o,er *e&i$n-increa&e* /ei$ht an* co&t."

O Redundancy!

M Com'en&ate (or uncertaint)"

M Lea* to o,er *e&i$n-increa&e* /ei$ht an* co&t."

O E8tensive testing!

M Si$ni(icant increa&e in e6'en*iture"

M Can lea* to 'ro*uct launch *ela)&"

M e&t en,ironment ma) be an ina*e+uate &imulation o( the o'eratin$

en,ironment"

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/onventional reliability +rediction

re=uires dataKbut

O A &ub&tantial number o( (ailure& nee* to ha,e alrea*)

occurre* (or the &)&tem to be a&&e&&e*"

O here i& a nee* (or reliabilit) *ata at 'art& le,el o( /hich

there a''ear& too little"

O !6i&tin$ *ata &ource& are o(ten not rele,ant to ne/

'ro*uct *e&i$n& becau&e o( the e,olution in material& an*

manu(acturin$ technolo$)"

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To co+e .it& suc& di,,iculties t&ere

is need to rely on

O Probabilit) theor) &o that one can mo*el

an* 're*ict (ailure or o'timal time to carr)

out P action&

O Per(orm relati,e com'ari&on in term& o(

'er(ormance &o that one nee* not rel) on theavailabilityo( lar$e number o( ,ailure data!

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T&an" youK any =uestions

01 Reliability and Availability Intro

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