Maintenance Cost VS Life of Machine: Engineering

and Economic Perspectives

Bimal Gautam
Department of Mechanical Engineering
Kathmandu University
Energy Technology
Email: bimalgautamz111@gmail.com

Abstract—This paper presents a comprehensive analysis of 100

the relationship between maintenance costs and machine life, Total Wear
integrating both engineering and economic perspectives. Through
examination of wear mechanisms, failure modes, and cost pat- 80 Material Loss
terns, we explore how maintenance requirements and associated

Wear Rate
costs evolve throughout a machine’s operational life. The study 60
provides both technical and financial frameworks for under-
standing maintenance cost dynamics, supported by mathematical
models and empirical data. 40

I. I NTRODUCTION 20
The relationship between maintenance costs and machine
life represents a complex interplay of technical deteriora- 0
0 2 4 6 8 10
tion and financial implications. This paper explores both the Operating Time
engineering mechanisms driving maintenance needs and the
resulting cost patterns throughout equipment lifecycle. Fig. 1. Wear Rate Progression Over Time

II. T ECHNICAL FACTORS A FFECTING M AINTENANCE

C OSTS 100
Total Cost
A. Wear Mechanisms 80 Fixed Cost
Maintenance Cost

The primary wear mechanisms affecting maintenance costs Repair Cost

include: 60
Wt = Wa + Wb + Wf + Wc (1)
40
Where:
• Wt = Total wear rate 20
FL
• Wa = Adhesive wear: ka H
F LS
• Wb = Abrasive wear: kb H 0
F nL
• Wf = Fatigue wear: kf H m
0 2 4 6 8 10
• Wc = Corrosive wear: kc te
−Ea /RT Machine Age

III. L IFE C YCLE C OST A NALYSIS Fig. 2. Components of Maintenance Cost Over Machine Life

A. Total Maintenance Cost Function

The total maintenance cost (TMC) can be expressed as: V. C OMPONENT L IFE P REDICTION

T M C(t) = Cf (t) + Cp (t) + Cr (t) (2) A. Bearing Life Calculation

For critical components like bearings:
IV. M ACHINE L IFE P HASES C p
L10 = ( ) (3)
A. The Bathtub Curve P
The relationship between failure rate and machine age Where L10 is the basic rating life, C is the dynamic load rating,
follows the characteristic bathtub curve: and P is the equivalent dynamic load.
 8 60 55
Early Life

Percentage of Total Cost

Useful Life
6 Wear-out
Failure Rate

40
30
4

20 15
2

0 0
0 2 4 6 8 10 12 Early Life Useful Life Wear-out
Machine Life
Life Phase
Fig. 3. The Bathtub Curve: Failure Rate vs Machine Life
Fig. 5. Distribution of Maintenance Costs Across Life Phases

Actual Cost
100 Linear Projection X. M ONITORING AND C OST C ONTROL
Cumulative Cost

A. Condition Monitoring Parameters

• Vibration analysis
• Oil analysis
50 • Thermography
• Performance monitoring
XI. C ASE S TUDIES
Analysis of industrial equipment shows typical cost distri-
0
0 2 4 6 8 10 butions:
Time • Early life (0-2 years): 15% of total costs
• Useful life (2-12 years): 55% of total costs
Fig. 4. Cumulative Maintenance Cost Over Time • Wear-out phase (12+ years): 30% of total costs

XII. C ONCLUSION
VI. C OST O PTIMIZATION S TRATEGIES The relationship between maintenance costs and machine
A. Preventive Maintenance Optimization life is governed by both technical and economic factors. Un-
The optimal maintenance interval can be determined by: derstanding the interaction between wear mechanisms, failure
s modes, and cost patterns enables optimal maintenance strate-
2Cp gies that balance reliability with cost-effectiveness. The visual
Topt = (4) representations and mathematical models presented provide a
Cf λ
framework for maintenance planning and cost optimization
Where: throughout the equipment lifecycle.
• Topt = Optimal interval
R EFERENCES
• Cp = Preventive maintenance cost
• Cf = Failure cost [1] R. K. Mobley, ”Maintenance Engineering Handbook,” McGraw-Hill
Education, 2014.
• λ = Failure rate [2] B. Bhushan, ”Introduction to Tribology,” Wiley, 2013.
[3] A. K. S. Jardine, ”Maintenance, Replacement, and Reliability,” CRC
VII. C UMULATIVE C OST A NALYSIS Press, 2013.
[4] J. Moubray, ”Reliability-centered Maintenance,” Industrial Press Inc.,
A. Cost Accumulation Pattern 2001.
VIII. C OST D ISTRIBUTION A NALYSIS [5] D. Palmer, ”Maintenance Planning and Scheduling Handbook,”
McGraw-Hill Education, 2012.
IX. E NGINEERING S OLUTIONS FOR C OST R EDUCTION
A. Design Improvements
• Optimized component geometry
• Enhanced lubrication systems
• Improved sealing mechanisms
• Better material selection