Scribd
Upload
128 views

Chapter Nine Failure Rate, Reliability and Maintainability

The document discusses reliability and maintainability concepts. It defines reliability as the probability an item will perform satisfactorily for a given time period under specified conditions. It describes the bathtub curve failure rate model and common root causes of failures during different periods. Methods for reliability analysis like Markov, fault tree analysis, and failure modes and effects analysis are introduced. Maintainability is defined as the probability an item will be restored to working condition, and key maintainability measures like mean time to repair are outlined.

Uploaded by

Simachew Addisu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
128 views

Chapter Nine Failure Rate, Reliability and Maintainability

The document discusses reliability and maintainability concepts. It defines reliability as the probability an item will perform satisfactorily for a given time period under specified conditions. It describes the bathtub curve failure rate model and common root causes of failures during different periods. Methods for reliability analysis like Markov, fault tree analysis, and failure modes and effects analysis are introduced. Maintainability is defined as the probability an item will be restored to working condition, and key maintainability measures like mean time to repair are outlined.

Uploaded by

Simachew Addisu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 24

Chapter nine

Failure rate, Reliability and


Maintainability
1.2. Root Cause of Equipment Reliability
Problems and Bathtub Hazard Rate Concept

Reliability is
 the probability that an item will perform its
stated function satisfactorily for the given time
period under the specified conditions.
 an important factor in equipment
maintenance
Root cause count….

Root Cause of Equipment Reliability Problems


based on data collected over a 30-year period :
1. Sales and marketing: 28%
2. Production scheduling: 20%
3. Maintenance: 17%
4. Production practices: 17%
5. Purchasing: 10%
6. Plant engineering:
Bathtub Count …
In reliability analysis, the hazard or time-
dependent failure rate of items follows the
shape of a bathtub
Bathtub Count …
Causes of Failure during the Burn-In Period
– Poor quality control
– Inadequate materials
– Incorrect use procedures
– Poor test specifications
– Incorrect installation or setup
– Poor manufacturing processes or tooling
– Incomplete final test
– Wrong handling or packaging
– Poor technical representative training
Bathtub count,…

Some of the causes of failures in useful life


period include :
insufficient design margins, incorrect use
environments, undetectable defects, human error
and abuse, and unavoidable failures
Some causes for the occurrence of wear-out
region failures are:
wear due to aging, inadequate or improper
preventive maintenance, limited-life components,
wear due to friction, misalignments, corrosion and
creep, and incorrect overhaul practices
1.2. Reliability Measures
Reliability measure Count..

Example 12.1
An electric motor times to failure are described
by the following probability density function:
Reliability measure count..
1.3. Reliability Networks
The reliability evaluation of most standard
networks occurring in engineering systems is
important
The networks that are commonly known in
engineering system are series, parallel, and
standby
Series Network
 If any one of the units fails, the system fails.
 A typical example of a series system is four wheels
of a car
Reliability network count..
Reliability measurement count..
Reliability measurement count..
Reliability measurement count....

Example
An aircraft has two independent and active
engines. At least one engine must operate
normally for the aircraft to fly. Engines 1 and 2
reliabilities are 0.99 and 0.97, respectively.
Calculate the probability of the aircraft flying
successfully with respect to engines.

Solution: There is 99.97% chance that the aircraft


will fly successfully with respect to engines.
9.4. Reliability Analysis Methods

Three methods are commonly used in the


industrial sector for reliability analysis:
Markov, fault tree analysis (FTA), and failure
modes and effect analysis (FMEA).
Falt tree analysis (FTA)
A fault tree is a logical representation of the
relationship of primary/basic events that lead to a
given undesirable event (i.e., top event)
It is depicted using a tree structure with logic
gates such as OR and AND.
FTA Count…
FTA Count…
The OR gate provides a TRUE (failure) output if one
or more of its input faults are present.
 In contrast, the AND gate provides a TRUE (failure)
output if all of its input faults are present.
Circle and rectangle symbols denote a basic fault
event and the resultant fault event which occur
from the combination of fault events through the
input of a gate, respectively.
The development or construction of a fault tree is
a top-down process (i.e., starting from the top
event moving downward).
• Example: A room has two light bulbs and one
switch. Develop a fault tree for the top event
room not lit. Assume the following:
• • The room is windowless.
• • The switch can only fail to close.
• • The room will only become dark if there is
no electricity, both light bulbs burn out, or the
switch fails to close.
FTA count..
FTA Count…

Probability Evaluation of FTA


• The probability of OR and AND gate output
fault event occurrence can be calculated using
Eqs. (12.46) and (12.47) below.
FMEA Count….

Failure modes and effect analysis (FMEA)


Failure modes and effect analysis (FMEA) is one of
the most widely used methods to evaluate design
at the initial stage from the reliability aspect.
The technique helps identify requirements for and
the effects of design change.
FMEA demands listing potential failure modes of
each system/equipment/device/part on paper and
its effects on the listed
subsystems/systems/parts/etc.
FMEA Count..

The basic steps used in performing FMEA are as follows:


1. Define system/equipment/item boundaries and associated
detailed requirements.
2. List all system/item components and subsystems
3. Identify each component, its associated failure modes, and
their descriptions.
4. Assign failure rate/probability to each identified component
failure mode.
5. List effect or effects of each failure mode on subsystem/plant.
6. Enter remarks for each failure mode.
7. Review each critical failure mode and initiate appropriate
measures.
1.5. Maintainability Terms and Definitions, Importance, and Objectives

Maintainability: The probability that a failed item/equipment will be restored to


acceptable working condition.
Maintainability engineering: An application of scientific knowledge and skills to
develop equipment/item that is inherently able to be maintained as measured
by favorable maintenance characteristics as well as figures of-merit.
Maintainability model: A quantified representation of a test/process to perform
an analysis of results that determine useful relationships between a group of
maintainability parameters.
Downtime: The total time in which the item/equipment is not in a satisfactory
operable condition.
Serviceability: The degree of ease/difficulty with which an item/equipment can be
restored to its satisfactory operable state.
Maintainability function: A plot of the probability of repair within a time given on
the y-axis, against maintenance time on the x-axis and is useful to predict the
probability that repair will be completed in a specified time.
The main objective of maintainability is to maximize equipment and facility
availability.
Maintainability Measures and Functions
• Various measures are used in maintainability analysis: for example, mean
time to repair (MTTR), mean preventive maintenance time, and mean
maintenance downtime.
• Maintainability functions are used to predict the probability that a repair,
starting at time t =0, will be completed in a time t. Some maintainability
measures and functions are presented below
• Meantime to Repair
• Mean time to repair (MTTR) is probably the most widely used
maintainability measure.
• It measures the elapsed time required to perform a given maintenance
activity. MTTR is expressed by

You might also like