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Outline
¨ Reliability
¨ Improving Individual Components
¨ Providing Redundancy
Outline - continued
¨ Maintenance
¨ Implementing Preventive
Maintenance
Maintenance © 1995
Corel
Corp.
Performance
¨ Information sharing
¨ Skill training
¨ Reward system
¨ Power sharing
Continuous Improved
improvement quality
Tactics for
Reliability and Maintenance
¨ Reliability Tactics
¨ improving individual components
¨ providing redundancy
¨ Maintenance Tactics
¨ implementing preventive
maintenance
¨ increasing repair capabilities
Fig 17.2
R = R1 * R2 * R3 * ...
Evaluating Maintenance
¨ Reliability
¨ Probability that an item will function for a given
time
¨ Mean time between failures (MTBF)
¨ Average time between failures of a repairable
item
¨ Failure rate
¨ Reciprocal of MTBF
Failure Rate (%)
Number of failures
FR(%) = * 100%
Number of units tested
Lifetime Failure Rates
“normal” failure Wearout
failure
Failure
rate Infant
mortality
and
improper use
failure
Lifetime
Mean Time Between Failures
1
MTBF =
FR(N)
Failures Per Operating Hour
Number of Failures
FR(n) =
Operating Time
Providing Redundancy
Breakdown Cost
Optimal Maintenance
Commitment
Contract for Preventive
Maintenance
¨ Compute the expected number of
breakdowns without the service contract
¨ Compute the expected breakdown cost per
month with no preventive maintenance
contract
¨ Compute the cost of preventive maintenance
¨ Compare the two options
Features of
A Good Maintenance Facility
¨ Well-trained personnel
¨ Adequate resources
¨ Ability to establish a repair plan and
priorities
¨ Ability and authority to do material planning
¨ Ability to identify the cause of breakdowns
¨ Ability to design ways to extend MTBF
Total Productive Maintenance
¨ Additional requirements of:
¨ 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
¨ Developing preventive maintenance plans that
utilize the best practices of operators,
maintenance departments, and depot services
¨ Training workers to operate and maintain their
own machines
Other Techniques for Establishing
Maintenance Policies
¨ Problem 1:
¨ California Instruments, Inc., produces 3,000 computer chips
per day. Three hundred are tested for a period of 500 operating
hours. During the test, six failed: two after 50 hours, two at
100 hours, one at 300 hours, and one at 400 hours.
¨ Find FR(%) and FR(N).
¨ Problem 2:
¨ If 300 of these chips are used in building a mainframe
computer, how many failures of the computer can be expected
per month?
ASSIGNMENT
¨ Problem 3:
¨ Find the reliability of this system:
0.92 0.90
¨ Problem 4:
¨ Given the probabilities below, calculate the expected
breakdown cost.
¨ Number of Daily
Break downs Frequency
0 3
1 2
2 2
3 3