RIPHAH INTERNATIONAL UNIVERSITY, ISLAMABAD

OPERATIONS MANAGEMENT
Lecture # 7:

MAINTENANCE & RELIABILITY

Humayun Akhtar Awan

WORLD
CLASS
RELIABILITY
EVERYTHING RIGHT,
FIRST TIME, EVERY TIME

NATIONAL AERONAUTICS & SPACE ADMINISTRATION

SPACE SHUTTLE PROGRAMME

Columbia, Discovery, Atlantis, Endeavour
Example of RELIABILITY failure: Challenger in 1986 (NASA almost
shut down)
Columbia has done 86 million miles, but is scheduled for 77 more
voyages till retirement
Maintenance requires scheduling for 01 million moving parts to
ensure reliability
600 computer generated maintenance jobs, with hundred of tasks
during three month turn around period between flights

INTRODUCTION
The results of failure can be disruptive, inconvenient,
wasteful and expensive in terms of money & human lives
Machine and product failures can have far-reaching effects
on an organizations operation, reputation and profitability,
whether it is an office or production floor
The objective of maintenance and reliability is to maintain
the capability of the system while controlling costs. A good
maintenance system drives out system variability
Maintenance includes all activities involved in keeping a
systems equipment in working order
Reliability is the probability that a machine part or product
will function properly for a specified time under stated
conditions
Interdependency of operator, machine and mechanic is a
hallmark of maintenance and reliability

RELIABILITY
Systems are composed of a series of individual
interrelated components, each performing a specific job.
If any one component fails to perform, for whatever
reason, the overall system can fail. The Chain is just as
strong as the Weakest Link
Two tactics:
Improving Individual components
Providing redundancy

IMPROVING INDIVIDUAL COMPONENTS

Because failure do occur, understanding their occurrence is an important
reliability concept
As the number of components in a series increases, the reliability of the
whole system declines very quickly
To measure reliability in a system in which each component may have its
own unique rate of reliability, the following equation is used:
System Reliability

Rs = R1 X R2 X R3 X . X Rn

Component Reliability is a design issue. The basic unit is Product Failure

Rate (FR)
FR (%) = Number of Failures X 100
No. of Units Tested
FR (N) = Number of Failures_______________
No. of Unit-hours of Operating Time

Mean Time between failures (MTBF) = _____

FR(N)

PROVIDING REDUNDANCY
To increase reliability, Redundancy is added
This is done by use of addition Backup
components in parallel
If one component fails, an alternate
arrangement is in place
Probability of
first component
working
(0.8)

Probability of
Probability of
second component X second component
working
Not working

+ [(0.8)

(1-0.8)] = 0.96

MAINTENANCE
Two types of maintenance:
Preventive Maintenance:
A plan that involves routine inspections, servicing and
keeping facilities in good condition to prevent failure
& to keep the system working without interruptions

Breakdown Maintenance:
Remedial Maintenance that occurs when equipment
fails and must be repaired on an emergency or
priority basis

Two tactics:
Implementing or improving preventive maintenance
Increasing repair capabilities or speed

IMPLEMENTING OR IMPROVING
PREVENTIVE MAINTENANCE
Preventive Maintenance implies that we can determine
when a system will need service or repair
For some products, failure in initial stages is possible,
called Infant Mortality.
Mortality This is due to improper use by
customer mostly. So firms test products for this prior to
shipment and sometimes after sales service includes
installation and training
Equipment history and replacing parts or components
before the time specified by OEM to be maintained

Maintenance Required
Time of Maintenance
Cost of Maintenance
Inventory of spares
Emergency spares supplier

INCREASING REPAIR CAPABILITIES

OR SPEED
Because reliability and preventive maintenance are
seldom perfect, most firms opt for some level of repair
capability
Enlarging or improving repair facilities can get the
system back in operation faster
A good maintenance facility should have the following
06 features:

Well-Trained personnel
Adequate Resources
Ability to establish a repair plan and priorities
Ability and authority to do material planning
Ability to identify the root cause of breakdown
Ability to design ways to extend MTBF
Equipped In-house maintenance facility or external vendors

TOTAL PRODUCTIVE MAINTENANCE

It combines TQM with strategic view of maintenance from
process equipment design to preventive maintenance
It involves the concept of reducing variability through
employee involvement and excellent maintenance records
It also involves:
Designing machines that are reliable, easy to operate and easy to
maintain
Emphasizing total cost of ownership when purchasing machines, so
that service and maintenance are included in the cost
Develop preventive maintenance plans that utilizes the best
practices of operators, maintenance departments and depot services
Training workers to operate and maintain their own machines

High utilization of facilities, tight scheduling, low inventory

and consistent quality demand reliability. Total productive
maintenance is the key to quality

TECHNIQUES FOR ESTABLISHING

MAINTENANCE POLICIES
Two other OM techniques have proven beneficial
to establishing maintenance policies: Simulation &
Expert Systems
Simulation helps in complex maintenance and
reliability decisions. Failure of parts, components
and systems can be simulated using a physical,
graphic or mathematical model.
Expert Systems are computer programs that mimic
human logic to assist staff in isolating and
repairing various faults in machinery and
equipment.

THANK YOU