17 Maintenance and Reliability 1. The Strategic Importance of Maintenance and Reliability Maintenance includes all activities involved in keeping a system’s equipment in working order. Reliability is the probability that a machine part or product will function properly for a specified time under stated conditions. The objective of maintenance and reliability is to maintain the eapability of the system while controlling costs. 4 tactics for improving reliability and maintenance: 1. Reliability tactics: a. Improving individual components. b. Providing redundancy. 2. Maintenance tactics are: a. Implementing or improving preventive maintenance. b. Increasing repair capabilities or speed. po FP Lecture Key: For a company to continue down the path to success, two important components needed are maintenance and reliability. For a system to be both maintained and reliable, it keeps the customers satisfied that their product will be of good quality. It also allows the company to keep its cost down because of so few repairs. Ml, Reliability A. Improving individual components 1. Computing system reliability: Ry=RiXR2X Ry XXRy Example: System Reliability The National Bank of Greeley, Colorado, processes loan applications through three clerks set up in series: If the clerks have reliabilities of .90, .80, .99, then the reliability of the loan process is, Ri Ro Ra 9 Rs 90 80 99, 370Solution: Ry= Ri xRoxR3 = (.90X.80)(.99) =.713 or 71.3% 2. Product Failure Rate FR(%) = (# of failures / # of units tested FR(%)) x 100% 3. Mean Time Between Failures MTBF = 1/ FR) Example: Failure Rate and Mean Time Between Failures (MTBF) ‘Twenty air-conditioning systems designed for use by astronauts in NASA space shuttles were operated for 1,000 hours at NASA’s Huntsville, Alabama, test facility. Two of the systems failed uring the test—one after 200 hours and the other after 600 hours. To compute the percentage of failures, we use the following equation: Solution: FR (%)= (# of failures / # of units tested FR (%) ) x 100% = (2/20) x 100% = 10% Next we compute the number of failures per operating hour: FR (N) = of failures / Operating time Where: Total time = (1000 hr) (20 units) = 20,000 units-hr Nonoperating time = 800 hours for 1* failure + 400 hours for 2™ failure = 1,200 hours per unit Operating time = Total time ~ Nonoperating time FR (N) = 2 (20,000- 1,200) = 0.000106 failure /unit-hr and because MIBF = 1 / FR) = 1/ 000106 = 9,434 br If the typical space shuttle trip lasts 60 days, NASA may be interested in the failure rate per trip: Failure rate = (failures/unit-hr) (24 hr/day) (60 days/trip) = (.000106) (24) (60) = .152 failure/trip Lecture Key: The system reliability is important because not only do you need to see how reliable each individual component is, but also, as a group, how reliable they are. As far as product failure rate, this is important because if the failure rate of a product is too high, the product then has to be reworked in some way to lower that rate. Lastly, mean time between failures, this is also important because if the product is continuously in the shop, maybe there is another alternative being that obviously this one is not working out as planned. 374B. Providing Redundancy 1. Redundancy is the use of components in parallel to raise reliabilities. 2. They “back up” components with additional components to ensure that if one component fails, the system has a resource to another. 3. ¢ Probability of Probability of Probability of first component | + (=n! coon x ( needing second ] working working component Example: System Reliability Using Parallel Components ‘The National Bank is disturbed that its loan application process has a reliability of only .713. ‘The bank decides to provide redundancy for the least two reliable clerks. Ry Ro R3 al 08 FL Solution: Ry = [(.90) + [9 * (1 ~.9)] * [(:80) + [8 * (1 —.8)] * (99) (.99) * (.96) * (.99) = .94 or 94% By providing redundancy, the National Bank has increased the reliability of the loan process from .713 to .94, Lecture Key: Redundancy increases the reliability of the different components of the process by adding a back up if the first component fails. Example 3 shows the increase of reliability. lll Maintenance A. Two types of maintenance: 1. Preventative Maintenance involves performing routine inspections and servicing and keeping facilities in good repair. 2. Breakdown Maintenance occurs when equipment fails and must be repaired on an emergency or priority basis. 3. Implementing Preventative Maintenance a. Implies that we can determine when a system needs repair or service. b. Infant Mortality is a high initial failure rate that may exist for many products, c. Once the product, machine, or process has settled in, a study can be made of the MTBF (mean time between failure) distribution. 4. We want to determine when preventative maintenance is economical. i. The more expensive the maintenance, the narrower the MTBF distribution (smaller standard deviation) ii, Preventative maintenance costs may be so incidental that it is appropriate even if MTFB distribution is flat. 4, Firms can maintain records of individual processes, machines, or equipment so a profile can be developed of the kinds of maintenance required and the timing of the maintenance needed. 372Total ' ' cose | XN Full cost of | oe Nf oes | reaktowns | | rransonarce gi 1 8 1 costs 8 i { eroakcc | | maineranca Provetive ‘ | 1 cae rmaitonanca . i cat . | J ‘ainionarse commitment Wainonarce come ‘Optima port owost cost maintenance potcy) (2) Traattional View of taintenance 5. Curves such as in Figure (a) seldom consider the full costs of a breakdown, Optimal por (owast ‘cosl maintenance polcy) {©} Fult Cost view ot Maintenance Many costs are ignored because they are not directly related to the immediate breakdown. 6. Figure (b) may be a better representation of maintenance costs. In Figure (b), total costs are at a minimum when the system does not break down. Lecture Key: This is a traditional view of the relationship between preventive maintenance and breakdown maintenance. Operations managers consider a balance between the two costs. On the one hand, allocating more resources to preventive maintenance will reduce the number of breakdowns. At some point, however, the decrease in breakdown maintenance costs may be less than the increase in preventive maintenance costs. At this point, the total cost curve will begin to rise. Beyond this optimal point, the firm will be better off waiting for breakdowns to ‘occur and repairing them when they do, Example: Preventive Maintenance Cost A CPA firm, specializing in payroll preparation, has automated much of its work. computerized approach has problems. the rate indicated in the table: Number of Breakdowns 0 1 2 3 Solution Number of Months Breakdowns Occur 2 8 6 4 Total: 20 The Over the past 20 months, printers have broken down at Each time a printer breaks down, the firm loses an average of $300 in time and service expenses. One alternative is to purchase a preventative maintenance service contract. There will still be breakdowns averaging I/month. The price is $150/month. Deciding whether firm will contract will require using a 4-step approach: Step 1: Compute the expected number of breakdowns (past history) if firm continues without service contract. 373Step 2: Compute the expected breakdown cost per month with no maintenance contract. Step 3: Compute the cost of preventative maintenance. Step 4: Compare the two options and select the one that costs less. #1 #ofBreakdowns | Frequency | # of Breakdowns 0 2 3 (Expected number = ¥ { (numberof x (corresponding of breakdowns) breakdowns) frequency) = (OL) + AY4) + (2)03) + BY(2) = 0+.4+.6+.6 = 1.6 breakdowns/month #2, Expected Breakdown Cost. = (Expected # of breakdowns) x (S per breakdown) = (1.6)($300) = $480/month #3. Preventative Maintenance $= ($ of expected breakdowns if contract is signed) + (Cost of Service Contract) = (1 breakdown/month\($300) + $150/month = 450/month #4, Because it is less expensive overall to hire a maintenance service firm ($450) than to not ($480), the firm should sign the preventative maintenance contract. 7. Increasing Repair Capabilities a. Repair capability is important because reliability and preventive maintenance are not perfect b. Six features required for a good maintenance facility: i. Well trained personnel ii. Adequate resources Ability to establish a repair plan and prio: iv, Ability and authority to do material planning v. Ability to identify the cause of breakdowns vi. Ability to design ¢. Managers must determine how maintenance will be performed. Lecture Key: Preventative and breakdown maintenance both deal with keeping equipment in working order. The main difference between the two types of maintenance is whether the equipment has already failed. Many times less costs are incurred when maintenance is done on equipment before it actually fails. However, due to the infant mortality rate, itis difficult to evaluate when equipment is going to fail prior to it actually failing. 374IV. Total Productive Maintenance A. Total Productive Maintenance ~ the concept of reducing variability through employee involvement and excellent maintenance records. B. Total productive maintenance includes: 1. Designing machines that are reliable, easy to operate, and easy to maintain. 2. Emphasizing total cost of ownership when purchasing machines, so that service and maintenance are included in the cost. 3. Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot service. 4, Training workers to operate and maintain their own machines. Lecture Key: Total productive maintenance is the practice of enabling employees to operate and maintain machinery in order to reduce costs. V. Techniques for Establi 1g Maintenance Policies ‘A. Simulation ~ Computer simulation is used to evaluate costs involved with maintenance decisions prior to the actual failure of machines. B. Expert Systems ~ Managers use expert systems to assist staff in isolating and repairing faults in machinery and equipment. Lecture Key: Simulation and Expert systems allow managers to determine future costs and pinpoint faults when they do occur. Simulation allows managers to estimate the future deterioration of machinery. 375CHAPTER 17 PROBLEMS Reli si Bailey's Bikes wants to determine the reliability of its newest bicycle. The company uses one vendor for all the necessary parts of this bike. Based on the reliabilities in the chart below, which of the three suppliers should Bailey's use? In other words, which has the best overal reliability? [CWendor™ Sam a A 96 94 Bo 99 96 ct 37 33 Solution: This is an example of a straight series of operations. The reliability of the system is calculated by simply ‘multiplying each part's reliability with the next par’s reliability Vendor: A=.99x.95x.96x.94= 84.9 Be 97x .92x.99x.96= 848 C= .94 x98 x.97x.93= 83.1 According to these reliabilities, Vendor A would be the best supplier. 82. The Hooley Dooley Restaurant will not open until certain standards are met. Most individuals have to prepare food and clean the restaurant. Each individual station has met the standard of 90%, but through the employees” work efforts, the manager realizes that to be efficient, the restaurant must have a reliability, of atleast 85%. If five employees are as follows in the below information, can the restaurant meet reliability standards? Reliability] Employee 1 Solution: This is an example of a straight series of operations. The reliability of the system is calculated by simply ‘multiplying each part’s reliability with the next part’s reliability Reliability ~ (,90) x (.95) x (92) x .90) x (90) = 6371 S3. The operating system of a marketing firm will not open until certain standards are met. Each salesperson has met the individual standard of 90%, but the senior partner of the firm also realizes that to be safe, the overall system must have a reliability of at least 85%. This includes number of sales, attention ratings, and customer satisfaction. Ifthe 6 marketers are as follows in the table, can the firm meet its standards? Marketer Reliability 1 95 2 i 94 3 T 96 4 t 31 3 33 6 98 | Solution: This is an example of a straight seties of operations, The reliability of the system is calculated by simply ‘multiplying each part’s reliability with the next part's reliability. Reliability = .95 x94 x.96x 91 x.93x.98 = .7110 = 71.10% So, the marketing firm is not reliable. 376S4. EZ Rider Car Company makes automobiles with lap seat belts on the driver and passenger side. The car ‘company must meet the safety standard of 90%. Since safety is so important, EZ Rider also includes airbags both on the driver and passenger side of the front seats. a. Does EZ Rider achieve its 90% safety standard? Yes, they achieve well beyond 90% (97.12%). Subsystem Relabiiy= Relabiliy= Backup : % 55 z + 98 2 3 = Z sr “tr Solution: This is an example ofa straight series of operations with backups (or parallel systems). The reliability ofthe system is calculated by the reliability of the main component (series) and the backup (parallel) together. You can then treat this reliability as the reliability of the subunit. Once you have calculated the reliability of the subunit, then treat as series of operations and multiply each subunit’s reliability with the next subunit’s reliability, £99 +1C-99%" 907) £98) 5 95 +101.95)* 9] * [98+ [1-94)* 95 999 9960 996 = 9712 $5. During tax season, printers are important. Before the next tax season comes, the company wants to back up some of their printers, They want to back up any printer with less than a 96% reliability value. All others stand alone. They want the overall reliability to be at least 90%, 095 0.95 0.96 099 099 0.95 [ 098 | L Solution: This isan example of a straight series of operations with backups (or parallel systems). ‘The reliability of the system is calculated by the reliability of the main component (series) and the backup (parallel) together. You can then treat this reliability as the reliability of the subunit. Once you have calculated the reliability ofthe subunit, then treat as series of operations and multiply each subunit’s reliability withthe next subunits reliability. 1961-96) 95)) * (99) © (98) 5 (954 10-95)" 95) 5198) = 98 + 99 #99 + OTS +98 = 9562 = 95.62% 1 ‘The operating system of the focal water control plant will not open the spillway unti all the individual control values have met certain standards. Each station has met the individual standard of 90%, but the ‘manager also realizes that to be safe, the overall system must have a reliability of at least 85%, Ifthe five subsystems are as follows in the below table, can the spillway meet its reliability standards? [Subsystem iabi 1 95 eee?) 99 a Sn a LoS 8 377Since the overall reliability is obviously important, the manager of the operating system of the local water control plant has decided to put backups on all the control values, Does the backup make a difference and increase the reliability to at least 85%? If the five subsystems are as follows in the below table, can the spillway mect the reliability standards necessary to open the spillway? =Main Reliability - Backy Bayou Gator Manufacturing has contracted three firms to design a new motor for their line of fishing boats. Due to the varying water compositions and changing weather, these motors must be put together very well. Before the company will buy the design from the winning firm, the prototype must achieve at least a 95% reliability rate on the company’s test course, which contains all the “normal” conditions that the boat is designed to accept. The motor has 5 basic subassemblies that must be judged on reliability Which firm should Bayou use? Firm eee 2 3 a (cena A a 98 omaaal| B 4 3 5, 95 4) c 37 t96 2 94 4 ‘What if Bayou Gator Manufacturing can buy each subassembly separately from the best firm? What isthe highest reliability level that Bayou could hope for inthis new motor? Use the previous problem's data ‘SuperBrakes wants to determine the reliability of its braking system for the latest large vehicles that car ‘manufacturers are selling. It uses one vendor as a supplier for all brake parts. Ifthe reliability for each ‘part were listed in the following table, what would be the best supplier? PART # Vendor 2 3 a A 95 2 | B 9. 4 oi Cc 94 95 96, D a7 98 2 6 #1 2 ” 378For its Industrial Braking Systems, SuperBrakes wants to determine the reliability of its braking system, Ituses the same vendors as its supplier for all brake parts. The sequence changes slightly for this system. If the reliability for each part were listed in the following table, what would be the best supplier? Would that change your overall answer for #6? _ _ PART# 1 A 94 c B 86 c 91 D 94 a 2 8 “4 Robert runs a rehab clinic for physical injuries that require stabilization and strengthening in specific ranges of motion. He is analyzing different lines of equipment to replace his existing equipment. There hhas been a revolution in designs since Robert last had to buy a piece of equipment. Also, there is intense ‘competition between competitors. With all the information and marketing campaigns in place, Robert doesn’t know how to make a mistake. Since repetition and consistency are essential to successfully rehab patients, Robert knows that he has to count on the machines to work. He contacted some of the ‘competitors’ recent customers and asked about the reliability of five specialty pieces of equipment. The information is summarized below. Machine ‘Supplier #1 ‘Supplier #2 | Supplier #3 Knee 98, 94 t 31 Elbow 31 95 98 ‘Ankle 99 94 95 Shoulder 90 3 33 ‘Back 99 94 34d From the information, calculate the reliability ofthe suppliers’ machines. Which supplier should Robert use to purchase his new equipment? What other considerations or concerns might Robert have? Calculate the following system's reliability 90 90 80 90 98 a7 90 90 90 90 90 90 90 3798 The Veggie Express is a new product that is composed of four parts. For the product to function as intended, all parts must work. Two of the parts have a 97 probability of working, and two have a.93, chance of working. What is the overall probability of the product working properly? ‘A new detergent injector was developed to use with washing machines and dishwashers. It has three separate hoses with pumps attached that feed the different detergents to the washings. All three hoses are ‘identical, but the detergents add varying wear to the hose and pumps. This explains the varying reliability rates for each component, The following information explains reliability rates for the three components, ‘Component T Reliability Hose/Pump #1 94 Hose/Pump #2 97 Hose/Pump #3) 99 380