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Section 1 - page 1
Benefits of R&M
Highly reliable and maintainable production machinery offers the means for producing
consistently high quality products at lower costs and at higher output levels. Successful
application of R&M techniques has a very positive effect on employee morale and pride since the
reduction in downtime also results in significant reduction in employee stress and frustration.
Table 1-1. R&M User/Supplier Benefits
User Benefits
Supplier Benefits
Improved profitability
MACHINE BUILD
35%
OPREATION
AND SUPPORT
50%
DEVELOPMENT
12%
CONCEPTION STAGE
3%
Section 1 - page 2
Emphasizing R&M practices during the conception and development stages can lower the total
LCC. By using R&M to minimize stress (electrical, mechanical, etc.), the equipment will be less
prone to failure during operation. This results in a decrease of the operation and support costs
that account for the bulk of total LCC.
A slight increase in spending to incorporate R&M practices during the conception and design
stages can dramatically lower the operation and support costs.
It is important to consider R&M at the early stage of a program. Studies have shown that as much
as 95% of LCC is determined during conceptual and development stages. Once new product
(equipment) has reached the build stage, therefore, only 5% opportunity remains to effectively
improve the reliability or maintainability of the product (equipment).
Examples of LCC Improvement: Intel Corporation is engaged in the design and manufacture of
solid-state devices. Intel has developed and is implementing a corporate strategy that addresses
the subject of reliability and maintainability in an aggressive, committed manner.
In portions of its assembly operation, Intel has improved the Mean Time Between Adjustments
(MTBA) from 5 minutes to 16 minutes. This improvement makes it possible for one operator to
run eight machines rather than four, a doubling of operator productivity. In addition, process
yields have been improved due to the elimination of scrap that resulted from the more frequent
shutdowns.
Intel's R&M program was also responsible for improving the Mean Time Between Failures
(MTBF) from 10 hours to 250 hours on its solid-state component wire bonding machines. This
improvement had the same effect as adding 30% capacity to the existing machine base. Another
benefit of this improved reliability lies in the fact that Intel was able to reassign the three line
technicians who previously served as "baby-sitters" to more productive work.
Your Example of LCC Improvement: Choose a product (equipment) that you are familiar
with. State your approach to improving the life cycle cost for the product (equipment). What
additional resources (time, money, technology, labor,...) are needed, and what are the foreseeable
benefits?
Example of Life Cycle Cost
Equipment Name:
Estimated Initial Cost:
Estimated Life:
Estimated Annual Operational Cost:
Current Status:
Recommended Modifications:
Section 1 - page 3
100
2
1
Reliability Functions
Rel [%]
0
0
10,000
Time to failure
Question: Looking at the Figure, state your findings regarding the relationship between
reliability and time? Which of the two curves represents a more reliable system? Why?
Response:
Section 1 - page 4
In the definition of reliability, three phrases were used. Those phrases were:
1)
Perform intended functions satisfactorily;
2)
For the specified period of time; and
3)
Under specified conditions.
What do we mean by "Perform Intended Function Satisfactorily"?
To understand this phrase better, let's define Failure.
FAILURE: An event when machinery/equipment is not available to produce parts at specified
conditions when scheduled or is not capable of producing parts or perform scheduled operations
to specification. For every failure, an action is required.
Unsatisfactory performance is subject to interpretation. Therefore it must be clearly defined at the
time of the contract. There will be various levels of failure based on the customer's level of
severity for incidents on the manufacturing equipment.
What do we mean by "Specified Time Period"?
Products deteriorate with use and even with age when dormant. This is especially true for wood
products. Longer lengths of usage imply higher chance of failure and hence lower reliability.
For design purposes, target usage periods must be identified. Typically identified usage periods
are:
Durability life that is a measure of useful life, defining the number of operating
hours until overhaul is expected or required.
What do we mean by "Specified Conditions"?
Products react to the environment in which they are being placed in. Different environments
promote different failure modes and different failure rates for a product. Therefore the
environmental factors which the product will encounter must be clearly defined.
Environmental factors such as: Temperature, Humidity, Vibration, Mechanical shock,
Immersion/splash, Pressure/vacuum, Contamination, Electrical noise, Electromagnetic fields,
Corrosive materials,..., must be addressed during the design stages of the equipment. These
environmental conditions must be thoroughly documented.
1.3 Association between Quality and Reliability
Lamberson lists quality characteristics as:
Section 1 - page 5
Quality is referred to as fitness for use. This comprises all phases of the life cycle of the
product including engineering, manufacturing, marketing and maintenance. This must be
addressed from the customers' standpoint. Company-wide quality control is a philosophy that
focuses on meeting customer needs and expectations throughout the life cycle of the product
while continuously improving the production process.
Quality Defects are defined as those which can be located by conventional inspection
techniques.
Reliability Defects are defined as those which require some stress applied over time to develop
into detectable defects.
Performance and Reliability: Engineering is concerned with designing and building products
for improved performance. This requires the designs to incorporate features that may tend to be
less reliable than the older systems with lower performances.
The trade-offs between performance and reliability are often subtle. Thus any product with both
improved performance and reliability is significant advance.
We usually improve performance through increased loading;
Decrease the weight of an aircraft increase in the stress level of structure
Increase in temperature to get thermodynamical efficient rapid corrosion in material
This approach to the physical limits of system increases number of failures.
Specifications for a purer material, tighter dimensional tolerance, ..., is required to reduce
uncertainty in the performance limits, and thereby permit one to operate close to these limits
without increasing the probability of exceeding them.
The performance of a system is often increased at the expense of increased complexity, this again
decreases reliability, unless compensating measures are taken.
Probably greatest improvements in performance is introduction of new materials or devices to
achieve a particular goal:
Section 1 - page 6
Ex: Military aircraft: An intermediate example in which reliability and performance are
balanced.
Ex: Commercial airliner: In this case, reliability is the overriding design consideration. Thus
degraded speed, payload, and fuel economy are accepted to maintain a very small probability of
catastrophic failure.
1.4 Definition of Reliability Measures
In this section, we will define:
Failure rate;
Section 1 - page 7
For example, a one-shift reliability of the machine with MTBF of 1,000 hour is:
R(t=1,000 hr.) = e-8/1000 = 0.992
=>
R8= 99.2%
There is 99.2% chance of running the equipment for 8 hours without encountering a failure. The
same equipment has only 79.4% chance of running for 100 hours without encountering a failure.
I recommend selection of an agreeable time frame over which reliability is to be sustained. An
example might be the 8-hour Reliability, denoted by R8, which represents the probability that
the machine will not fail during an 8-hr shift.
Example 1: The failure rate of a component is 0.001 hr-1.
a)
Find the MTBF.
b)
c)
What is the probability that the component will not fail in a one-month continuous
operation.
Example 2: Given the reliability function R(t) = e-t/1000, where t is time to failure in hrs.
a)
Find the 100 hour reliability.
b)
c)
If 1,000 devices are placed in operation. How many will still be operating at 100 hrs?
Section 1 - page 8
b)
c)
d)
In 100 hours of operational time, how many failure would you expect?
What is the Relationship Between MTBF of a System and MTBFs of its Components?
Most systems consist of several subsystems. Occasionally we need to combine MTBFs from
different subsystems to calculate the MTBF for the main system. An example is to analyze a
design in which we may have data on the MTBFs of the different subsystems used in the new
design.
Example 4: Consider a system in which one subsystem has an MTBF of 25 hours. On the
average, in 100 hours of uptime, there will be 4 failures. Using the relationship between MTBF,
number of failures, and operating time it is seen that:
MTBF = (Uptime)/(Total Number of Failures)
MTBF1 = 100/4 = 25 hrs.
Now consider adding a second subsystem with a MTBF of 20 hours to the previous system. This
subsystem is expected to have 5 failures in 100 hours of uptime.
MTBF2 = 100/5 = 20 hrs.
How do we combine the MTBFs to obtain the MTBF for the main system?
Obviously, we can expect 4+5 = 9 failures in 100 hours of operation, therefore:
MTBFS= 100/9 = 11 hours!
that is the system fails more often than each of the subsystems.
Can you figure out the rule? The rule is to combine the failure rates
S=
1+ 2
or equivalently:
that is:
Section 1 - page 9
MTBF
50,000 hrs
20,000 hrs
200,000 hrs
10,000 hrs
10,000 hrs
2X10 hr -1
5X10 -5 hr -1
5X10 -6 hr -1= 0.5 X 10-5 hr -1
1X10 -4 hr -1= 10 X 10 -5 hr -1
1X10 -4 hr -1= 10 X 10 -5 hr -1
a)
b)
-5
Example 6: Consider a work-station for which the subsystems failure rates are:
Subsystem
Load/unload mechanism
Mechanical actuator
Electronics
Hydraulics
(1/hr.)
0.00003
0.00001
0.000005
0.0004
MTBF(hrs)
33,333
100,000
200,000
2,500
a)
b)
MTBF and Failure Rate are two related measures of the Reliability of the equipment or product.
The next question is: How do we measure the Maintainability?
Maintainability is a characteristic of design, installation and operation, usually expressed as the
probability that a machine can be retained, or restored to, specified operable condition (returned
to a serviceable state) within a specified interval of time when maintenance is performed in
accordance with prescribed procedures.
In what follows some Maintainability Improvement Strategies is discussed.
Section 1 - page 10
Section 1 - page 11
Modularity: Modularity requires that designs be divided into physically and functionally distinct
units to facilitate removal and replacement. It allows design of components as removable and
replaceable units for an enhanced design with minimum downtime. Modular design concepts
typically are thought of in terms of electrical black boxes, printed circuit boards and other quick
attach/detach electrical components. These concepts are also applicable to the mechanical
elements of production equipment.
Advantages of modularity are:
New designs can be simplified and design time can be shortened by making use of
standard, previously developed building blocks.
Match marking of all fasteners (nuts, bolts, screws) fixed, adjustable or critical
Section 1 - page 12
Section 1 - page 13
6.
in which system failure rate is the sum of failure rate for different modes;
Comparing the Maintenance Load for different Modes of Failure; initiate design action
for failure modes that create a high load on the maintenance function.
Example 7: During the equipment design and development phase (using the Failure Mode
Analysis), the following three failure modes were identified, and the corresponding failure rates
and times to repair were estimated. Use the information to estimate MTTR and to rank those
failure modes.
Failure rate per 1000 hrs
Maintenance Load ( x t)
Hydraulic leak
10
10
Torn part
10
20
Conveyor jammed
0.5
Failure Mode
MTTR =
Section 1 - page 14
Example 8: Consider the following situation in which the MTBF and TTR for five different
modes of failure are listed:
Subsystem number
MTBF (hour)
1,000
1.5
5,000
4.0
10,000
1.0
2,500
2.5
500
0.5
Calculate MTBF and MTTR for the system and rank the significance of different modes of
failure from the maintenance load point of view.
Subsystem
Failure Rate(
)
Time to Repair
Maintenance Load
1
2
3
4
5
MTBF =
MTTR =
Example 9: Consider the following situation in which the MTBF and TTR for six different
modes of failure are listed:
Subsystem number
MTBF (hour)
120
4.0
100
5.5
600
3.0
1,000
1.0
1,500
0.5
750
1.5
Section 1 - page 15
Calculate MTBF and MTTR for the system and rank the significance of different modes of
failure from the maintenance load point of view.
Subsystem
Time to Repair
Maintenance Load
1
2
3
4
5
6
Total
MTBF =
MTTR =
1.6 The Relationship Between R&M and Availability
What is Availability and how is it related to R&M?
Availability (A) is the probability that at any time, the system is either operating satisfactory or
is ready to be operated on demand, when used under stated conditions.
The goal of availability engineering and management is to determine and achieve the availability
performance necessary to the manufacturer's corporate, operating, company, and plant-level
business performance and leadership.
Remember that the plant does not have to be shut down to experience reduced availability. When
many plant items fail, they do not shut down the plant. Nor do they always reduce its production
level. However, the plant's characteristic availability has been reduced.
A simple example is a plant with two pieces of equipment. One is a spare. When one fails, the
other is placed in service. Thus, the plant's real-time production level is not reduced. However,
the probability of maintaining that level over a period of time is substantially less.
The availability can be looked at as the ability of an equipment (under combined aspects of its
reliability, maintainability and maintenance support) to perform its required function at a stated
instant of time.
Availability includes the built-in equipment features (R&M) as well as in-plant maintenance
support function (M).
Section 1 - page 16
RELIABILITY + MAINTAINABILITY
=>
AVAILABILITY
During the later phases of the life of the product, the availability is calculated using the
actual data on operating time and downtime; that is:
A = Operating Time/Net Available Time
in which:
Net Available Time = Operating Time + Unplanned Downtime
We will see that the two equations result in the same value for A.
Example 10: Calculate the availability for the following welder machine:
Subsystem
MTBF (hr)
Failure rate
1.
2,400
1.25
2.
4,000
1.0
3.
200
2.25
4.
1,500
0.5
5.
7,000
3.0
Maint. Load
TOTAL
MTBF =
MTTR =
A=
One useful tool for measuring the performance of a piece of equipment is OEE.
Overall Equipment Effectiveness (OEE) is a comprehensive measure of equipment
effectiveness. The measurement encompasses:
1) What percentage of time the machinery is available (availability).
2) How fast the machinery is running relative to its design cycle time (speed ratio or
performance efficiency).
3) What percentage of the resulting product is within quality specifications (yield).
Section 1 - page 17
b)
c)
Calculate Availability.
d)
e)
f)
Section 1 - page 18
Section 1 - page 19
Few Notes:
1)
Reliability was defined as the probability that a component, device, or system will
perform satisfactory for at least a given period of time when used under stated conditions.
2)
3)
The concept of reliability tells us that any given product has a built-in reliability function
that relates its reliability to time and decreases as time progresses.
Note also that:
Reliability is a probability concept.
Reliability theory is a subset of quality control, but Q.C. function deals primarily
with new products under inspection, whereas reliability deals with products in
service.
We shall consider the system as a set of interacting components working together
as an integrated whole.
A system is said to fail when it ceases to perform its intended function
4)
When there is a total cessation of function, the system has clearly failed, but often it is
necessary to define failure quantitatively to consider failure through deterioration or
instability of function. Examples:
A motor that is no longer capable of delivering a specified torque,
A machine that no longer processes parts at its designed capacity.
5)
The way in which time is specified in the definition of reliability varies considerably,
depending on the nature of the system under consideration. Therefore in any
intermittently operated system (say a switch), we must specify whether calendar time or
the hours of operation is to be used.
6)
7)
Several quantities can be used to characterize the reliability of a system including mean
time to failure and failure rate, and in the case of repairable systems mean time to repair
and availability.
8)
Section 1 - page 20
Figure 1-6. Five Phases of Manufacturing Machinery and Equipment Life Cycle
The reliability activities taking place during each of these phases of the product life may be quite
different. For instance in the project definitions, the objectives of the systems are set forth in the
form of one or more functional requirements. For an ergonomically designed chair, the exact
requirements and for a computer desk, the exact dimensions and specifications are specified. In
addition, the environment in which the system is to function must be determined (i.e.: the range
of temperature and humidity, the concentrations of dust or other contaminates,). Finally, the
service life to which the system is to be designed must be specified.
From such requirements, a conceptual design is formulated that in broad form outlines how the
system is to function, and provides the general plan for its construction. From the functional
requirements comes the definition of failure, and thus of reliability. Reliability requirements may
then be set, and the trade-offs between reliability, cost and functional requirements may be
examined as the design proceeds into the detailed phase.
Section 1 - page 21
The conceptual design must be converted into a detailed set of drawings and specifications from
which the system can be built. During this phase, maintenance requirements and procedures are
also likely to take place. As the design proceeds, experiments, testing, and analysis are required
to choose between alternatives, to solve problems, and to predict the performance of subsystems
or components.
Reliability considerations should permeate this stage of design in setting safety factors and design
margins, eliminating unnecessary complexities, translating system reliability criteria into
reliability requirements for subsystems, and on setting time intervals for inspection, maintenance
and replacement of parts subject to wear.
Note that in this stage, the detailed examination of potential failure mechanisms and models is
most beneficial, for often they may be eliminated or mitigated without too much expense. In the
later stages of the design of the process, prototypes are built and the first reliability tests may be
performed.
Historically, reliability considerations during the manufacturing of a system are related to the
practices of quality control. Reliability in manufacture is monitored and controlled, and use of
statistical Q.C. techniques for reliability testing on manufactured item is exceedingly important.
Verification of end product reliability by testing to failure is not possible in large one-of-a-kind
system. Thus very stringent acceptance criteria on components, careful supervision and control of
the construction process and an elaborate set of proofs or acceptance tests are necessary in such
situations.
Reliability and Phase 1 - Concept Phase
The first phase is research and limited development or design usually resulting in a proposal.
During this phase both the user and the supplier must work together to establish system
requirements. It is recommended that the user team include machine operators, maintenance
personnel and product engineers. The supplier team should include MM&E suppliers.
Machinery mission and environmental requirements are defined during this phase. Also
identified are safety issues, desired goals for reliability and maintainability and life cycle cost.
Simultaneous (concurrent) engineering can be introduced at either Phase 1 or Phase 2 depending
on the particular situation and MM&E.
Reliability and Phase 2 - Development/Design Phase
The development/design phase determines the majority of the life cycle cost. The issues from the
concept phase are incorporated. Safety, ergonomics, accessibility and other maintainability issues
are designed into the system. R&M allocation requirements are formalized.
Components and component suppliers should be selected based on the predictive R&M statistics
they provide. It is recommended that MM&E suppliers utilize methods highlighted in the SAE
guideline to assure that R&M goals will be met.
The design review is a procedure for assuring that the planned design is likely to, or does in fact;
meet all requirements in the most cost-effective way, considering all variables and constraints.
Section 1 - page 22
1)
2)
3)
4)
5)
6)
7)
8)
9)
Section 1 - page 23
During this phase maintenance should be performed regularly. For an R&M initiative to be
successful, the MM&E and component suppliers must have access to maintenance records and
R&M data bases.
Reliability and Phase 5 - Decommissioning and/or Conversion Phase
This phase is the end of the expected life of the machine. During this phase machine may require
decommissioning due to an increasing failure rate that has resulted in increasingly expensive
maintenance or may be rebuilt to a good-as-new state.
In another possible situation, the machine may still be in good condition but the production needs
have changed requiring the machine to go through major conversion to be used for production of
other products.
When either the decommissioning or conversion action is taken, the feedback from the user plant
should be recorded and all the information should be used for R&M growth and continuous
improvement in future generations of machinery.
________________________
Notes:
Section 1 - page 24