Chapter 7-01

Reliability and Maintainability

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Introduction
Failure: “non conformance to some defined performance

criterion”.
Quality: “conformance to specification”.

Reliability: the probability that an item will perform a required

function under stated conditions for a stated period of time.

Or,
it is the probability of non failure in a given period; and as such

is an extension of quality in to the time domain.

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 cont.…

Maintainability: The probability that a failed

item will be restored to operational

effectiveness within a given period of time
when the repair actions is performed in
accordance with prescribed procedures.
Or,

it is the probability of repair in a given time

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 Cont…
Why do we need to talk of reliability and maintainability?

a. Reliability
determines frequency of repair
fixes spares requirements
determines loss of revenue

b. Maintainability
determines downtime
determines manpower requirement
affects training
test equipment

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Cont…

Activities involved to achieve good R and M

a) Design
b) Manufacture
c) Field service Operation

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 Activities involved to achieve good reliability
and maintainability

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 Inter dependence of R and M
Reliability and Maintainability are interdependent for
three basic reasons.
I. The design and assurance activities required to achieve R and
M, in many cases are the same.

II. Maintainability is a parameter that greatly contributes to the

reliability of a system.

III. Both R and M contribute to the overall availability of the

system.

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 Reliability

Reliability is defined as the probability that a device will perform its intended
function for a specified period of time under stated conditions. The terms used in
this definition need some attention.
 The term “intended function” used to describe equipment performance, makes

it possible to identify what constitutes non-performance (failure) of the

equipment.
 “Performance under stated conditions” refers to operational and environmental

conditions or stresses that the equipment may experience during its useful
lifetime.
 The definition of reliability involves a time constraint which is not unusual. No

product lasts forever;

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 Classification of failures
By Cause
Production-related failures
Stress related failures
Misuse failure
Interest weakness failure
Wear out failure
Maintenance-induced failure

By Suddenness
Immediate failure
Gradual degradation failure

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 Cont…
By Degree
 Catastrophic failure
 Intermediate failure
 Partial failure
By Result
 Critical failure
 Major failure
 Minor failure
By Definition
 Applicable to the specification
 Not applicable
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 Functional failure
Any equipment must fulfill all the functions as set by the user
and must also satisfy the performance standards. The function
can be split into two categories: primary and secondary
functions.

 Primary functions: This category includes the functions such as

speed, output, product quality, etc. which are the functions why
the equipment was procured.

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 Cont…
 Secondary functions: This category includes such functions

like safety, control, operational efficiency, compliance to

environmental regulations, etc. These are the functions
which the equipment is expected to fulfill in addition to the
primary functions.

The occurrence which is likely to stop the equipment from performing to

standard all the functions expected is some kind of failure. The failed state
of an equipment is known as functional failure, and this occurs when the
equipment is unable to fulfill a function to a standard of operation which is
set by the user.
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Cont…
 The performance standard used to define a functional failure is
set by the user.
Example: Leakage problem

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 Cont…
The following are important points to be
considered in setting performance standards.

1. Performance standards must be clearly established

before the failure occurs.
2. Performance standards used to define failure must be
set by operations (production) and maintenance
people working together.
3. The performance standard defines the proactive
maintenance required to avoid failure.

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 Failure Mode:
 A failure mode is defined as any event which is likely to cause a

functional failure of an equipment. Failure modes are classified

in to three groups.

i) Falling capacity: when the initial capability of the equipment falls

below the desired performance, we have falling capacity of the
equipment.

The main causes for reduced capability are:

 deterioration due to wear & tear

 lubricant failure, mud, disassembly(falling apart),

 human error
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 Cont…

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 Cont…

ii) Increase in desired performance: when desired

performance rises above initial capability of the
equipment, there is failure of equipment. The reasons
for increase in desired performance are:
 sustained, deliberate overloading,

 sustained, unintentional overloading,

 sudden, unintentional overloading,

 Incorrect process materials which are out of specifications.

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 Cont…

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 Cont…
iii) Initial Incapability: when the equipment is not capable of
doing what it is expected to do from the outset we have initial
incapability and the equipment is unfit for operation.

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 Failure Effects:
 Failure effects describe what happens when a failure mode

occurs. In describing failure effects the following must be noted.

A. Evidence of failure:
 Is the failure evident to operating crew?

 Is the failure accompanied by obvious physical effects?

 Does the equipment/machine stop functioning as a result of the failure?

B. Safety and environment hazards:

 Is it possible that some one could get hurt?

 Are environmental regulations and standards breached?

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 Cont…

C. Production effects:
 Is process stoppage caused?
 How is production affected?
 How long is the downtime associated with the failure?
D. Secondary effects:
 How is product quality affected?
 Is customer service and satisfaction affected?
 What is the increase in the operating cost?
21  What secondary damages are caused?
 Cont…
E. Corrective action:
 What must be done to repair the failure?
 What resources are required for the repair?
 To make a comprehensive failure mode and effects analysis one

needs to have information about the modes and effects which

are obtained from various sources including:
 the manufacturer/supplier of the equipment,

 other users of the equipment,

 the people who operate on and maintain the equipment.

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 The Whole-life Equipment Failure Profile:
(The Bathtub Curve)
 The whole-life of equipment (failure) may be divided into three

major distinct periods:

a. infant mortality period, or early failure

b. useful life period

c. wear-out period
 The failure rate curve, commonly known as the bathtub curve, is

the sum of three separate over-lapping failure rate distributions

known as burn-in (early failure), random failure, and wear-out
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failure.
 The Bathtub Curve

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 Cont…
 The decreasing failure rate known as early failures, or

infant mortality, or burn-in, is usually related to

manufacture and quality assurance.
 The constant failure rate known as useful life or random

failure is stress related.

 The increasing failure rate known as wear-out is due to

damages causing wear processes

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 Reasons for burn-in failures

 inadequate quality control

 inadequate manufacturing methods

 substandard materials & workmanship

 wrong startup & installation

 inadequate processes and human error

 inadequate handling methods

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 Reasons for useful life failures

unexplainable causes

human error, abuse, natural failures

undetectable failures

low safety factors

higher random stress than expected.

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 Causes for wear-out failures

inadequate maintenance

wear due to friction

wear due to aging

wrong overhaul practices

corrosion failure

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 Effect of PM on equipment failure rate

burn-in useful life wearout

failure
rate overall failure curve
(bathtub curve)

wearout failure

effect of PM in elongating
useful equipment time
random failure

early failure
t1 t2 time

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 The End!!

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