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MAINTAINABILITY

&
AVAILABILITY
Terminology
Availability Measure of the degree to which an item is in an operable and committable
state at the start of a mission when the mission is called for at an unknown
(random) time.
Dependability

Measure of the degree to which an item is operable and capable of performing
its required function at any(random) time during a specified mission profile,
given item availability at the start of the mission. See Availability.
Capability A measure of the ability of an item or system to achieve mission objectives
given the conditions during the mission
Inherent R & M Value


Measure of reliability or maintainability that includes only the effects of an
item design and its application, and assumes an ideal operation and support
environment
Maintainability


The measure of the ability of an item to be retained in or restored to specified
condition when maintenance is performed by personnel having specified skill
levels, using prescribed procedures and resources
Maintenance All actions necessary for retaining an item in or restoring it to a specified
condition
Maintenance,
Corrective
All actions performed as a result of failure, to restore an item to a specified
condition. Corrective maintenance can include any or all of the following
steps: Localization, Isolation, Disassembly, Interchange, Re-assembly,
Alignment and Checkout.
Maintenance, Event


One or more maintenance actions required to effect corrective and
preventative maintenance due to any type of failure or malfunction,
false alarm or scheduled maintenance
Maintenance,
preventive
All actions performed in an attempt to retain an item in specified
condition by providing systematic inspection, detection, and
prevention of incipient failures
Maintenance,
scheduled
Preventive maintenance performed at prescribed points in the items
life
Maintenance Time An element of downtime which excludes modification and delay time
Maintenance,
unscheduled
Corrective maintenance required by item conditions
Mean- Maintenance -
Time
The measure of item maintainability taking into account
maintenance policy. The sum of preventive and corrective
maintenance times, divided by the sum of scheduled and
unscheduled maintenance events , during a stated period of time.
Terminology
Mean-Time-Between-
Failure (MTBF)
A basic measure of reliability for repairable items: The mean
number of life units during which all parts of the item perform
within their specified limits, during a particular measurement
interval under stated conditions.
Mean-Time - Between-
Maintenance(MTBM)
A measure of the reliability taking into account maintenance policy.
The total number of life units expended by a given time, divided by
the total number of maintenance events(scheduled and unscheduled)
due to that item.
Mean-Time-To-
Failure(MTTF)
A basic measure of reliability for non-repairable items: The total
number of life units of an item divided by the total number of
failures within that population, during a particular measurement
interval under stated conditions.
Mean-Time-To-
Repair(MTTR)
A basic measure of maintainability: The sum of corrective
maintenance times at any specific level of repair, divided by the total
number of item failures during a particular interval under stated
conditions.
Terminology
Planning & Strategies
Maintainability & Availability Planning:
Maintainability engineering is performed for the following
reasons:
To achieve ease of maintenance through design, reducing
maintenance time and cost, (increasing availability)
To estimate maintenance and equipment downtime. This
will determine the need for redundancy, in order to
increase availability.
To estimate system availability by combining
maintainability data with reliability data
To estimate labor, hours, time, and other resources for
proper maintenance





Designing and developing maintainable products and systems
provides guidelines for establishing a maintainability program:
Prepare program plan
Perform maintainability analysis
Prepare inputs to maintenance concept and plan
Establish maintainability design criteria
perform design trade-offs
predict maintainability parameter values
incorporate maintainability requirements in subcontractor specs
Integrate other items
Participate in design reviews
Establish data collection, analysis and corrective action system
Demonstrate achievement of maintainability requirements
Prepare maintainability status reports





Maintainability Program
An analysis of customer needs and requirements can determine
the maintainability and availability requirements for a system
or component.

The customer needs may include:
Expected operating time per unit time
Downtime, maintainability time, or availability constraints
Operational/ambient environment (i.e. polar, tropic, severe)
Types of diagnostic and maintenance support equipment
Maintenance skill levels
Maint & Availability Requirements
A measure of the degree to which an item or system can be
expected to achieve a set of specific mission requirements, and
which may be expressed as a function of availability,
dependability, and capability.

SE= Availability x Dependability x Capability

SE= Mission Reliability x Operational Readiness x Design
Adequacy

System Effectiveness
Reliability Time Relationships




Time, active That time during an item is in an operational inventory
Time, administrative That element of delay time, not included in the supply delay time
Time, alert That element of up time during which an item is assumed to be in
specified operating condition and is awaiting a command to perform
its intended mission
Time, delay That element of down time during which no maintenance is being
accomplished on the item because of either supply or administrative
delay
Time, down(down time) That element of active time during which an item is not in condition
to perform its required function (Reduces availability and
dependability)
Time, inactive That time during which an item is in reserve
Time, mission That element of uptime required to perform a stated mission profile
Time, modification The time necessary to introduce any specific change(s) to an item
improve its characteristics or to add new ones
Time, not operating That element of uptime during which the item is not required to
operate
Time, reaction That element of uptime needed to initiate a mission, measured from
the time command is received
Time, supply delay That element of delay time during which a needed replacement item
is being obtained
Time, up( uptime ) That element of active time during which an item is in condition to
perform its required functions
Uptime ratio A composite measure of operational availability and dependability
that includes the combined effects of item design, installation, quality,
environment ,operation, maintenance, repair and logistic support.
The quotient of uptime divided by uptime plus downtime
Useful life The number of life units from manufacture to when the item has an
unrepairable failure or unacceptable failure rate
Wear out The process which results in an increase of the failure rate or
probability of failure with increasing number of life units
Maintenance strategies should be chosen to ensure a high
level of availability while controlling cost. Preventive
maintenance does not improve the inherent reliability of the
system. Preventive maintenance will maintain the reliability
level of useful life, keeping the failure rate low. It will also delay
the onset of were, thus increasing the length of useful life.
A single unit, such as a pump, could be considered to be a
system. Or the pump could be considered to be a component of a
larger system. In either case, system reliability is at the highest
level if all units are in their useful life phase. Preventive
maintenance strategies such as reliability-centered maintenance
and predictive maintenance are proactive and require the
replace or components of the system that are nearing the end of
their useful life or entering wear-out. Replacement is made
before failure occurs. Condition-based maintenance is reactive
and is a corrective maintenance strategy. Replacement is made
after failure occurs.
Maintenance Strategies
Predictive maintenance assumes that the operator can detect the
imminent failure of a unit. This detection can be by observation,
analysis, or using test equipment. The analysis of an oil sample or the
measurement of increased vibration might indicate were and an
increasing failure probability. If the increasing failure probability can
not be detected by the operator, a reliability-centered maintenance
strategy could be adopted. This strategy use the predicted failure
distributions to determine the optimum replacement time for units
about to enter the wear-out phase. Replacement of units that are
entering the wear-out portion of the bathtub curve will maintain the
system reliability at the useful life level.
It is possible that any maintenance action can negatively impact
reliability by inducing failure modes due to the maintenance action.
These maintenance induced failures are similar to the early-life failures
due to the manufacturing or installation of a system. An effort should
be made during design to ensure that standard preventive maintenance
action can be preformed quickly and a low risk of introducing problems
due to the maintenance actions.





Predictive & Reliability Centered Maintenance
Maintainability
The measure of the ability of an item to be retained or restored to a specified
condition when maintenance is performed by personnel having specified skill
levels, using prescribed procedures and resources, at each prescribed level of
maintenance and repair.
Maintainability is most commonly measured by mean time to repair(MTTR)

Probability of Repair within the Allowable Downtime:
To calculate the probability of performing a maintenance action within an
allowable time interval use:




t =Allowable downtime
MTTR=Expected downtime(MTTR)

Example 8.3: What is the probability of completing a maintenance action
within 5 hours if the MTTR=7 hours?
Solution:
=1-0.4895=.5105

There is approximately a 51% probability of completion.


The average length of failures during a mission length of time T is T. The
number of failures which cannot be repaired within the allowable time is
given by:


Where: = failures per hour

Maintainability Allocation:
Maintainability allocation is similar to reliability allocation . Individual
equipment maintainability should be derived from the requirements of total
system.
Commonly used method for predicting MTTR of system is:





The number of failures that can be repaired within a time frame=
Availability
A measure of the degree to which an item is in the operable and
committable state at the start of a mission, when the mission is called
for at an unknown (random) time.
The three common measures of availability are:
Inherent Availability(A
1
)
Achieved Availability(A
A
)
Operational Availability(A
o
)


The measure of Inherent(potential) Availability(A
1
):




The measure of Achieved (Final) Availability (A
A
) :



Where : MTBMA is the mean time between maintenance actions both
preventive and corrective.
MMT is the Mean Maintenance Action Time, and MMT is further
decomposed into the effects of preventive and corrective maintenance and
is given as:



The measure of Operational(actual) Availability (A
o
) :
Where: MDT is the mean down time.
The instantaneous availability,(probability) that an item will be
available at time t is:
When t is large, the expression reduces to:
The system steady state unavailability=
Availability for constant failure rates
Series Configuration
Parallel Configuration
Preventive Maintenance Analysis
Objective of preventive maintenance is to ensure that the probability of
failure of equipment is minimized

Preventive maintenance decisions will depend on factors such as
distribution of failure times, cost of repairs, cost of down time

Time to failure distribution pattern in a system have major influence on
the replacement strategy

Following example shows optimization of replacement intervals to
minimize total cost

Given a decreasing hazard rate , it is best to not replace the part.

Given a constant hazard rate, scheduled replacement does not
reduce failure rates.

Given a increasing hazard rate, scheduled replacement reduces
failure rates.

Given a nearly failure free, but increasing hazard rate, scheduled
replacement will make for nearly zero failures.

Decreasing hazard rate,
scheduled maintenance will
return the part to the top of the
curve.
Constant hazard rate ,
replacement of a part will
result in the same probability
of failure as before.
Increasing hazard rate,
scheduled replacement of a part
will reduce the probability of
failures.
Increasing hazard rate with near
failure free life, scheduled
maintenance will ensure near
failure free probability.
Corrective Maintenance Analysis
Corrective maintenance should aim at quick repair, accurate diagnosis so
that the same fault is not repeated.

Measures of overall effectiveness would include MTBF and MTTR.
MTBF should be high while MTTR should be low.

Maximising the MTBF requires good diagnostic skills and tools, trained
technical persons, adequate tools that are located easily and quickly

Machines and equipment should be accessible for repairs. Layout of the
equipment should therefore be planned for accessibility during breakdown.

Data collection system should facilitate separate measurement and analysis
of preparation time , fault isolation time, active maintenance and delays.
As per MIL-HDBK-472, corrective maintenance can be analyzed as seven
steps:
1. Localization: Determining system fault without using test equipment
2. Isolation: Verification of system fault using test equipment
3. Disassembly
4. Interchange or replace defective parts
5. Reassembly
6. Alignment
7. Checkout

Reduction of repair time implies that time for each step should be reduced

Time to repair could be severely impacted when required spare parts are
not available


Testability
.

A test strategy should be developed for performing
measurements on a specific item or program. Test programs
usually occur at the end of development and production segments
and are used to determine if the design requirements have been
achieved. Test strategy includes all testing done on a product.
Testability is an important design feature.
Testability affects reliability, since production tests which are not
detected by testing can lead to failures in service, and circuits (or
complex systems) which are difficult to diagnose are more likely
to be inadequately or incorrectly repaired. Complex systems,
either mechanical or electronic, can benefit from good testability
principles.
The maintainability of a system is influenced by the ability to
detect a system fault and to isolate the component that has failed.
Testability
The testing requirements for a system should provide for a
method to detect a system fault and isolate the failed component:
In some cases, such as for a complex system, the requirement
could be met with a built-in test system.
by providing easily accessible test points for critical
measurements using external test equipment

The testability of a system must be developed as part of the
system design.

Built in test (BIT)
The testing of complex electronic systems such as
laboratory instruments, printed circuit boards, etc. are
made easier with built-in test(BIT) facilities or ports.

BITs can increase system availability and user
confidence, but can also provide false conditions if
BIT components malfunction.

Optimum Parts Replacement
It is generally assumed that the total cost of a
maintenance failure is greater then the cost associated
with a scheduled PM action.

The optimum time between maintenance actions is found
by minimizing the total cost per unit time.
PMs can be performed at constant intervals or upon
failure of the part or system. The optimum point would be
at the point where the total of maintenance and failure
costs are minimal. Other models for PM strategy are:

1. Constant interval replacement policy
2. Preventive replacement at predetermined age
3. Optimum replacement, under minimal repair
4. System shocks, time independent
5. System shocks, time dependent
6. Group maintenance
7. Inspection policy
8. Periodic inspection and maintenance
9. Continuous monitoring
Preventive Maintenance
Spare Part Analysis
The spare part inventories needed for equipment and
machinery should not approach the raw material
levels required for production needs. Spare are
necessary due to factors such as:

Long spare lead times (weeks, months, or years)
Avoidance of expensive production downtime
Penalties for late deliveries (as a supplier)
Unreliability of suppliers(as a producer)
The MTTR calculation assumes that spare parts are readily
available. This means that spares must be in inventory when
they are needed. If there is waiting time to obtain a spare, the
unit downtime will increase and availability will suffer.
If the unit has a constant failure rate, the probability of
requiring no more than r replacement units can be found
using the cumulative Poisson distribution.
The probability of having r or fewer failures in operating time t
if the unit is operating with a constant failure rate of is
If preventive maintenance required spare parts, the number of spares
necessary is a function of the operating time and the maintenance
cycle. The number of spares required for preventive maintenance is
the product of the maintenance cycle and the total operating time. The
total number of spares that must be kept in inventory is a function of
the delivery time, the cost of maintenance the inventory, and the
availability requirement.

A unit that operates an average of 2000 hours per year has a constant
failure rate


The maintenance strategy is to replace the unit every 5000 operating
hours. In a five- year period:
a. How many spares will be necessary for preventive maintenance?
b. With a.90 probability, how many spares will be necessary for
corrective maintenance?
b. P (r )= 0.9


From the cumulative passion tables in appendix N:
P(r=2)=.92
t=1.0

With a probability of .92 the number of spares needed for
corrective maintenance is no more then two.
Solution:
The operating time in a four-year period is t=5 x 2000 =10,000
hours

The preventive maintenance cycle is 1/5000 hours

The number of spares required for preventive maintenance is
n=(1/50000)x(10,000)=2

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