MS-57

Management Programme

ASSIGNMENT
SECOND SEMESTER
2016

MS-57: Maintenance Management

Program Title:MP

Enrolment No: ID1356210

Name: Prajwol Raj Aryal

Course Code: MS-55

Address: Tokha-10, Kathmandu
Course Title: Logistics and Supply Chain Management
Signature:
Assignment Code: MS-57/ TMA/SEM - II /2016
Partner Institution (PI) Code: 9602
Date of Submission:

ASSIGNMENT

CourseCode

MS-57

CourseTitle

Maintenance Management

Assignment Code

MS-57/TMA/SEM-II/2016

Coverage

All Blocks
st

Note: Attempt all the questions and submit this assignment on or before 31 October, 2016 to
the coordinator of your study centre.

1. What is reliability centred maintenance? What are the important steps involved in
implementingitin anyplant?

2. What is the importance of maintenance budgeting? Give the advantage of Zero Based
Budget.

3. A remote control unit has25 components in series.Each component has a reliabilityof

0.999. What is the reliability of the remote control unit? If it is desired to havea
reliabilityof 0.996 for 3000 hours of operation, what should be the failure rate of each
component? Assume that the time to failure for each component is exponentially
distributed.

4. Define hazard rate the discuss the three periods or regions of the life cycle of a unit or
device as illustrated bythe bath-tubcurve.

5. How can be questionnaire for Maintenance Audit prepared? What is the main difference
of audition result areas compared to auditing management processes?

6. Write short notes on the following:

a) Maintenance windows
b) Cost Absorption and Cost Apportionment
c) Designand Maintainability
d) MaintenanceAudit

1. What is reliability centered maintenance? What are the

important steps involved in implementing it in any plant?
Answer:
Reliability centered maintenance is a systematic approach to determine
maintenance requirements of any physical asset in its operating context. It
focuses on preserving the functions of equipment not on preserving the
equipment itself. By identifying the nature of equipment failures, it specifies
actions that reduce the consequences of equipment failure like damaged
equipment, possible injury, unnecessary downtime resulting in production loss
and ultimately, reduction in profits.
Operations identify the functions and performance standards while maintenance
identifies the types of failures. Maintenance then defines the most appropriate
maintenance strategies to predict or prevent each failure and brings them together
as a planned maintenance program. Both then cooperate in carrying out the
program, often with specific operator tasks. Thus, the implementing team can
attain better understanding of how the equipment functions and generate quality
information for future use. This information is used to monitor progress, measure
gains analyze results and record events to identify new applications and benefits
of reliability centered maintenance.
The important steps involved in implementing reliability centered maintenance
are as following:
1. Select the most critical equipment
2. Identify the functions of the equipment
3. Establish performance standards
4. Determine types of failures
5. Enumerate consequences of failures
6. Rank the consequences of failures
7. Apply the most effective maintenance strategies
8. Establish most effective maintenance plan

2. What is the importance of maintenance budgeting? Give the

advantage of Zero Based Budget.
Answer:
Maintenance budgeting is important for following reasons:
1. Budget necessitates the establishment of a program and regulates and emphasizes
performance within that program. You cannot prepare a budget without first
establishing a complete program, after which changes in your program will reflect
as variances in your budget.
2. It encourages participation and promotes understanding within managers and
employees. By witnessing your budgetary problems they can come to a better
understanding of the superintendents position and the problems he faces.
3. It requires that all expenditures be specifically labeled, whereby they immediately
gain identity. In other words, expenses must be listed under a particular budgeted
item.
4. The budget identifies immediate needs for the coming year. Budget variances point
out areas of concern, such as too much labor being used in one area, possibly
suggesting the purchase of a new piece of maintenance equipment.
5. large budget variances reflect unusual and unexpected problems

6. It provides for continuity of operations, especially helpful when managing officers

change.
7. It provides the superintendent with a vehicle to evaluate his maintenance program.
8. A good budget builds the superintendents credit with his members. That is, an
excellently conditioned course achieved within the limits of an approved budget, is a
feather in the superintendents hat.
9. Budgets regulate inventories. It restricts the purchase and storing of unneeded
supplies.
Zero-based budgeting helps in identifying areas of wasteful expenditure, and if desired, can
also be used for suggesting alternative courses of action. Followings can be listed as
advantages of zero based budgeting:
1. Efficient allocation of resources, as it is based on needs and benefits rather than
history.
2. Drives managers to find cost effective ways to improve operations.
3. Detects inflated budgets.
4. Increases staff motivation by providing greater initiative and responsibility in
decision-making.
5. Increases communication and coordination within the organization.
6. Identifies and eliminates wasteful and obsolete operations.
7. Identifies opportunities for outsourcing.
8. Forces cost centers to identify their mission and their relationship to overall goals.
9. Facilitates more effective delegation of authority

3.

A remote control unit has 25 components in series. Each

component has a reliability of 0.999. What is the reliability of the
remote control unit? If it is desired to have a reliability of 0.996
for 3000 hours of operation, what should be the failure rate of
each component? Assume that the time to failure for each
component is exponentially distributed.

Answer:
Here,
Total number of components in series =25
Reliability of each component = 0.996
Hence, Reliability of remote control unit

= (0.996)25
=0.905

Now,
For Desired reliability of 0.996 for 3000 hours of operation:
System Reliability, R(t)=0.996 and Hours of operation, t=3000
Assuming that the time to failure for each component is exponentially distributed,
We have, R(t)=e- t
Where, = system hazard rate

Substituting the values of R(t)=0.996 and t=3000, we get

0.996=e-3000
Taking natural logarithm on both sides of above equation we get,
ln 0.996= -3000 ln (e)
or, -0.004=-3000
Hence, System hazard rate, =
Now since the given system has 25 identical components in series, and we know
that system hazard rate for series system is the sum of the hazard rates of
individual components, h(t).
Hence for this case,
25h(t)==

Or, h(t)=
Now, Since we know that :
h(t)=

where,

h(t)=hazard rate,
f(t)=failure density and
r(t)=reliability for each component (supplied as 0.999 by question) ,
We get,
f(t)=
or, f(t)=

or, f(t)=
Hence, required failure rate f(t)= 5.328 10-8 per hour.

4. Define hazard rate. Then, discuss the three periods or regions of

the life cycle of a unit or device as illustrated by the bath-tub
curve.
Answer:

Hazard rate is the measure of instantaneous rate of failure, thatis, the probability of a failure
between time t and t+t given that there were no failures up to time t. The concept of
hazard rate is more often used in reliability and maintenance studies and denoted by h(t) or
Z(t).
Mathematically, hazard rate,
Where f(t) = failure density function, and
F(t)=

= failure distribution function.

But, reliability, R(t)= 1-F(t)

Therefore, h(t)=
The Bath-tub curve is a plot of the hazard rate, h(t), against time , which denotes the life
cycle of the component or device. The life cycle of a unit or device can be sub divided into
three distinct periods or regions.

1. Early failure or initialfailure, or running failure, or infant mortality region:

When a batch of new items just produced or assembled is placed in operation, the
initial failure rate is generally somewhat higher than that encountered a short time
later. This mainly due to initial failures of components owing to weaknesses or
manufacturing defects which are not found during inspection. Since the defective
units are eliminated during the initial failure period, this period is also known as the
debugging or burn-in period.
2. Incidental or random failure region: After the initial failures, for a long period of
time fewer failures are reported. This is the middle region of the bath tub curve in
which fewer failures are reported. This is the middle reason of bath tub curve in
which fewer failures take place but it is difficult to determine their cause. In general,
they seem to occur when the environmental or operational stresses exceed the
design strengths of the components, but it is difficult to predict either the
environmental stress or part strengths meeting up to them as deterministic functions
of time.
3. Wear-out failure region: As time passes, the units get worn out and begin to
deteriorate. A deterioration sets in, many failures occur. This is because of the fact
that a gradual change in the values of the parameters determining the performance
of the unit results and when the parameter values go beyond the limits of
admissibility, the unit fails. The changes of parameters in this region are irreversible

and generally are in the form of physio-chemical or metallurgical degradation. This

region is called the wear out failure region and in this period the hazard rate
increases.

5. How can be questionnaire for Maintenance Audit prepared?

What is the main difference of audition result areas compared
to auditing management processes?
Answer:

The auditors prepare a detailed questionnaire on various issues of concern in

maintenance management. Issues of concern in maintenance management is likely to
include the following bench marks: maintenance costs, maintenance materials
management performance, maintenance management processes, IT systems usage for
maintenance, preventive maintenance system, predictive maintenance system,
maintenance planning and scheduling through work order system and OperationMaintenance interface. Depending upon the location, type and production objectives all
possible pitfalls are identified and laid as questionnaire to be later used for the purpose
of maintenance audit. Subject matter expert is an important and additional strong tool
usually employed by auditors to prepare a maintenance audit questionnaire.
Audit of management systems is one of many benchmarks required for Maintenance
Audit. The scope and issues of maintenance audit includes many other benchmark titles
such as maintenance costs, maintenance materials management performance, IT
systems usage for maintenance, preventive maintenance system, predictive maintenance
system, maintenance planning and scheduling through work order system and
Operation- Maintenance interface apart from management processes. However, the
benchmark- maintenance management process has various sub-parameters within to be
audited viz vision and leadership, maintenance organizational structure and spare parts
management process.

6. Write short notes on the following:

a) Maintenance windows
A maintenance window is a defined period of time during which planned outages and
changes to production services and systems may occur. The purpose of defining
standard maintenance windows is to allow clients of the service to prepare for possible
disruption or changes. Maintenance windows arise or are made to arise because of one
or more of following reasons:
1. Variations in demand for product
2. Production scheduling
3. Change in production tools, catalyst changes, equipment cleaning etc.
4. Availability of standby (or redundant) plant and or due to inter-stage storage.
5. As a result of statutory safety work.

b) Cost Absorption and Cost Apportionment

Cost absorption means allotment of overhead expenses to cost units. Overhead
absorption is usually achieved by the use of one or a combination of overhead recovery
rates. An example of cost absorption would be the application of factory overhead costs
to processing departments using a pre-determined overhead rate.

Cost apportionment means the allotment of proportions of items of cost of cost centers
or cost units. Cost apportionment is also referred to as Cost allocation. Cost centre has
been defined as a location, person or item of equipment for which costs may be
ascertained and used for the purpose of cost control, whereas, a cost unit is a unit of
quantity of product service or time in relation to which costs may be ascertained and or
expressed. Cost apportionment includes choosing the object of costing, accumulating
the costs that relate to the object of costing and choosing the method to identify those
costs. Usually, the apportionment or allocation of costs would be done based on
machine-hours, direct-labor hours etc.

c) Design and Maintainability

The maintainability is a combined qualitative and quantitative characteristic of material
design and installation which enable the accomplishment of operational objectives with
minimum expenditure including manpower, personal skill, test equipment, technical
data and facilities under operational environment conditions in with scheduled and
unscheduled maintenance will be performed.
The concept of design is concerned about manufacturing and installing a specific
system or product under some pre specified conditions. One of the most important
factors set as condition for design is maintainability. Alternative system designs and
configurations of different module sizes have alternate reliability and maintainability
values and require different resources for maintenance. Maintainability may be given
less importance in one shot applications like missile and rocket propulsion, where
reliability is highly important. But in most of the general industrial machines and
equipment, maintainability has to be given due consideration.

d) Maintenance Audit
Maintenance audit is an audit undertaken to consider the status of maintenance function
in various installations. Maintenance audit considers various maintenance factors like
availability, reliability, maintainability and safety. Key result areas targeted by
maintenance audit are: maintenance costs, maintenance materials management
performance, maintenance management processes, IT systems usage for maintenance,
preventive maintenance system, predictive maintenance system, maintenance planning
and scheduling through work order system and Operation- Maintenance interface.
Various benefits are associated with the concept of maintenance audit such as
compliance towards various laws and standards, support comparison, identify areas for
improvement, national and international certifications and prepare towards popular and
prestigious awards.