Reliability and Maintenance
Management
4
Basic Concepts of Maintenance
Introduction
Manufacturing Operating ….. Maintenance
Design Materials Usage
Process Environment
Performance of Engineered
objects
Degradation & Failure
Mechanisms
2
Maintenance
• Maintenance involves functional checks, servicing, repairing/ replacing
of devices, equipment, machinery, infrastructure
• Maintenance Policy is a set of rules describing triggering mechanism of
maintenance actions
3
Maintenance Actions
• Maintenance Actions* include inspections, compliance tests,
monitoring, routine maintenance, overhaul, rebuild, repair, turnaround
maintenance, design out maintenance (DOM) etc.
• Maintenance actions can be carried out at any level of decomposition
of an engineered objects
* Read pages 75/76 for definitions of maintenance actions 4
* Read pages 76-81 for
explanatory text
Maintenance and Performance
6
Maintenance Actions & System Restoration
• Perfect Maintenance: Restores to As
Good As New (AGAN) condition
• Imperfect Maintenance: Restores to
between AGAN and pre-maintenance
condition
• Minimal Maintenance: Restores to As
Bad As Old (but functional) condition
• Worse Maintenance: Accidentally
causes system worsening
• Worst Maintenance: Same as Worse,
but causes further faults/
breakdowns too
Volosencu, C. , (Ed.). (2017).
System Reliability. IntechOpen.
https://doi.org/10.5772/66993
7
Uptime and Downtime
• Uptime: Restores The interval between two downtimes during which
the object is available for operation
• Downtime: The time interval where the object (product or plant) is
not operational and is undergoing either Preventive Maintenance or
Corrective Maintenance
8
Warranty & Maintenance
• Normal (Base) Warranty: manufacturer’s assurance to customers that the
engineered object shall perform satisfactorily. The contract specifies the
performance of the object, owner’s responsibilities, and warrantor’s
responsibilities upon object’s failure to meet the stated performance
• Manufacturer carries out remedial actions to rectify any failures over a
specified warranty period
• Warranty may be separately paid for, and may be extended
• Warranties play an increasingly important role in most consumer and
commercial transactions
10
Types of Warranties
• For standard products, most common type is the non-renewing
Free-Replacement Warranty (FRW), which can be:
• One-dimensional non-renewing FRW policy: Repair/ replacement
for failed items free of charge up to a specified time
• Two-dimensional non-renewing FRW policy: Repair/ replacement
for failed items free of charge up to a specified time or usage limit
Blischke and Murthy (1994)
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Types of Warranties
‣ For custom built products, warranties can be complex since buyers are not
usually aware of all the details of infrastructure/ plants/ system/ product they
are purchasing - for example a subway system of rails, trains and stations
etc. or a military system such as a warship, aircraft or missile system
‣ In such complex purchases, it is better to be assured of reliability of the
purchased infrastructure/ plants/ system/ product - preferably throughout
the life cycle
‣ thus warranty arrangements such as reliability improvement warranty
(RIW)
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Types of Warranties - RIW
• RIW extends the notion of a basic consumer warranty to include guarantees on the
reliability of the object and not just on its immediate or short-term performance
• Particularly appropriate in the purchase of complex, repairable equipment that is
intended for relatively long use
• Aim is to negotiate warranty terms that will motivate a manufacturer to continue
improvements in reliability - sometime under a negotiated Service Level Agreement
(SLA)
• Contractor’s fee is based on the ability to meet the warranty reliability
requirements. These often include a guaranteed MTBF
13
Types of Products w.r.t. Maintenance
• Products can be divided into three categories:
‣ A: Standard consumer products
‣ B: Industrial and commercial products
‣ C: Defense products
14
Maintenance Policies
• From a business perspective, maintenance policy for infrastructure/ plant/
system/ product/ component depends on a large number of factors, primarily
warranty arrangements
• Purchases of complex systems usually include purchasing comprehensive
Integrated Logistics Support (ILS) - which aims to decrease life-cycle cost of the
system and decrease demand for logistics by optimising maintenance systems
• Such arrangements usually include developing comprehensive maintenance
policies for complete life of the system (even after expiry of warranties or
contract)
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Key Issues in Maintenance for Policies
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Maintenance Policies Dimensions/ Variables
• Whether the policy is at component or product/ system level
• Level of expected degradation at various levels and high priority failure
mechanisms
• Monitoring/ Inspection intervals (continuous, discrete)
• Item usage (continuous, intermittent)
• Whether the parameters are known
• Time horizon/ product life-cycle
• Repair/ replacement (Minimal, Imperfect, Perfect)
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Elements of Effective Maintenance
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Questions?
