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Assignment 3

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Bimal Gautam
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4 views2 pages

Assignment 3

Uploaded by

Bimal Gautam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Maintenance Cost versus Maintenance Commitment

Bimal Gautam
Department of Mechanical Engineering
Energy Technology
Kathmandu University
Dhulikhel, Nepal
bimalgautamz111@gmail.com

Abstract—This paper analyzes the relationship between main- 100


tenance costs and maintenance commitment in industrial sys- Breakdown Cost
tems. Through mathematical modeling and graphical analysis, 80 Preventive Cost
we demonstrate the optimization point between preventive and
breakdown maintenance costs, establishing a framework for Total Cost
60

Cost
effective maintenance strategy development. The study provides
quantitative insights into the trade-offs between different main-
tenance approaches and their financial implications.
40

I. I NTRODUCTION 20
Maintenance strategy optimization is crucial for industrial 0
operations, directly impacting both operational efficiency and 0 2 4 6 8 10
financial performance. This study examines the relationship Maintenance Commitment
between various maintenance costs and the level of main-
tenance commitment, providing insights into optimal main- Fig. 1. Relationship between maintenance commitment and various cost
components
tenance strategy selection. The analysis focuses on three
primary cost components: breakdown maintenance, preventive
maintenance, and total maintenance costs. • K2 is the cost coefficient
II. T HEORETICAL F RAMEWORK • x is the maintenance commitment level
A. Cost Components III. O PTIMIZATION A NALYSIS
The total maintenance cost (TMC) can be expressed as the A. Total Cost Function
sum of breakdown maintenance cost (BMC) and preventive The total maintenance cost function can be expressed as:
maintenance cost (PMC):
T M C = K1 e−ax + K2 x (4)
T M C = BM C + P M C (1)
B. Optimal Point Determination
B. Breakdown Maintenance Cost
The optimal maintenance point occurs where:
The breakdown maintenance cost typically follows an ex-
ponential decay relationship with increased maintenance com- d(T M C)
=0 (5)
mitment: dx
Solving for x:
BM C = K1 e−ax (2)
−aK1 e−ax + K2 = 0 (6)
Where:
• K1 represents the maximum breakdown cost
1 aK1
• a is the decay constant xopt =ln( ) (7)
a K2
• x is the maintenance commitment level
IV. G RAPHICAL A NALYSIS
C. Preventive Maintenance Cost
V. C OST O PTIMIZATION S TRATEGY
Preventive maintenance cost demonstrates a linear relation-
To achieve optimal maintenance cost, organizations should:
ship with maintenance commitment:
1) Monitor the current position on the total cost curve
2) Adjust maintenance commitment levels to move toward
P M C = K2 x (3)
the minimum point
Where: 3) Regularly reassess cost parameters to account for:
• Equipment aging
• Technology updates
• Operating conditions changes
VI. I MPLEMENTATION F RAMEWORK
A. Data Collection Requirements
To implement the optimization strategy, the following data
must be collected:
• Historical breakdown frequencies
• Repair costs per incident
• Preventive maintenance labor costs
• Equipment downtime costs
• Spare parts inventory costs

B. Monitoring and Control


The optimization process requires:

T M Cactual − T M Coptimal
∆T M C = × 100% (8)
T M Coptimal
Where ∆T M C represents the deviation from optimal cost.
VII. C ASE S TUDY
Consider an industrial pump system with the following
parameters:
• K1 = $50, 000 (Maximum breakdown cost)
• K2 = $5, 000 (Preventive maintenance cost coefficient)
• a = 0.3 (Decay constant)

Applying equation (7), the optimal maintenance commit-


ment level is:
1 0.3 × 50, 000
xopt = ln( ) = 2.3 (9)
0.3 5, 000
VIII. C ONCLUSION
Understanding the relationship between maintenance com-
mitment and associated costs is crucial for developing effective
maintenance strategies. The optimal point between preventive
and breakdown maintenance costs provides a target for main-
tenance planning and resource allocation. The mathematical
model presented in this paper provides a framework for orga-
nizations to optimize their maintenance strategies and reduce
overall maintenance costs.
R EFERENCES
[1] A. K. S. Jardine and A. H. C. Tsang, “Maintenance, Replacement, and
Reliability: Theory and Applications,” CRC Press, 2013.
[2] R. K. Mobley, “An Introduction to Predictive Maintenance,”
Butterworth-Heinemann, 2002.
[3] J. Moubray, “Reliability-centered Maintenance,” Industrial Press Inc.,
1997.
[4] L. R. Higgins, R. K. Mobley, and D. Wikoff, “Maintenance Engineering
Handbook,” McGraw-Hill Education, 2008.
[5] D. Palmer, “Maintenance Planning and Scheduling Handbook,”
McGraw-Hill Education, 2012.

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