Kuliah 1 - Intro

8/2/2019 Kuliah 1 - Intro

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Rekayasa Perawatan danKehandalan

(Maintenance and Reliability Engineering)

Intro

Muhammad Adha Ilhami

1st Edition


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Objectives

Understanding distribution of failure of a

machine or system.

Able to determine which distribution is fitted

to failure pattern of a machine.

Able to calculate reliability of a machine

Capable of designing maintenance scheduleon designed reliability of a machine or system.



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Rules

Cell phone must be silent or offline.

No sandals are allowed

Be in class in time, You cant be late, notolerance at all (Except for those who work)

Assignment must be collected on time, zero is

for those who late. Quiz is given without notice.



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Requirements & Valuation


Requirements:

Statistics

Probability Theory

Valuation:

Mid Test 25

Final Test/Final Assignment 30

Assignments 30 Attitude and activity in Class 10

Quiz 15


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Classroom Schedule (1)


Wk Topics Sub Topic Specific Objectives Activities

1 Introduction 1. Maintenance Overview

2. Maintenance Topology

Understanding how

maintenance important for

assuring production and

productivity.

Classroom

2 3 Probability & Distribution 1. A Short Probability Theory

2. Normal, lognormal,

exponential, and weibulldistribution

Understanding the relation of

distribution function and its

probability.

Classroom

and

assignment

4 Availability 1. Definition of available

time, loading time, and

operational time.

2. Calculation of availability

performance

Able to identify loading time,

operational time, and available

time.

Classroom

5 Reliability andmaintainability

1. Calculation of reliability2. Calculation of reliability as

a function of time

Able to determine reliability in agiven period of time.

Classroomand

assignment

6 7 System Reliability 1. Reliability Block Diagram

Design (RBD)

2. System reliability

calculation based on RBD

Capable of designing RBD and

calculation of system reliability

Classroom

and

assignment


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Classroom Schedule (2)


Wk Topics Sub Topic Specific Objectives Activities

8 M I D T E S T

9. Maintenance Schedule 1. Determining MTBF from

Reliability Density Function

2. Scheduling maintenance

from MTBF calculation.

Able to schedule planned

maintenance to perform required

reliability

Classroom and

assignment

10 - 11 System Performance

Measurement

1. Performance effecting

factors of a machine or system

2. Calculation of OEE (OverallEquipment Effectiveness) and

OPE (Overall Performance

Effectiveness)

Able to measure performance of

a machine or system.

Classroom and

assignment

12 - 13 Total Productive

Maintenance

Conceptual Framework of

Total Productive Maintenance

Understanding TPM frameworks Classroom

14 Predictive Maintenance 1. Prediction Factor

2. Prediction Instruments

Able to determine instruments

for predicting failure

Classroom and

assignment

15 Reliability Centered

Maintenance

Conceptual framework of

RCM

Understand RCM frameworks Classroom

16 F I N A L T E S T


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Literature

Suzuki, Takutaro, 1994, TPM in Process Industries, JapanInstitute of Plant Maintenance, Productivity Press,Portland, Oregon.

Walpole, Myers, Ye, 2007, Probability & Statistics forEngineers & Scientists, 8th Edition, Pearson Education,London.

Borris,Steven, 2006, Total Productive Maintenance,Mc.Graw-Hill.



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Knowing Failure

What is failure?

What failure happens?

Why failure occurs? How failure occurs?

In what pattern failure occurs

How failure effecting production, safety,and reliability?



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failure

Failurerefers to thestate or condition of notmeeting a desirable or

intended objective, andmay be viewed as theopposite of success.

Also, inability toproduce work inappropriate manner



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Where it occurs?

Equipment / machine failure on productionfloor worn out bearing, pump, pressureleaks, broken shaft, overheated machine etc.

Equipment failure in office failure of powersupply, air-conditioned system, computernetwork, photocopy machine

Vehicle failure brake, transmission, engine,cooling system



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Why failure occurs?

Improper design

Improper materials

Improper process Improper assembly or installation

Environment/external factors

Neglect maintenance schedule/procedures Improper operation


The making


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Failure Cause


30% - Manufacturing Errors

26% - Design Errors

23% - Maintenance Errors 18% - Material Selection

3% - Operation/Handling


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How Failure Occurs:

See This!



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Failure Rate Pattern

Every tool/machine has a very specific and unique failure pattern. Most researchers believe this pattern:


Burn-in testthats why You need to warm up your motor cycle.


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You should remember this



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Distribution Fitted



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Failure Effects

Reducing availability, automaticallyreducing production capacity and thenreducing income.

Increase repair cost which contributing tothe total cost.

Increase potential loss such as safety andhealth.



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Failure Impact

Impact variance can be minimum to veryserious situation such as mortality andcatastrophic.



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Example of Failure Impact



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Maintenance Definition

British Standard Glossary of terms (3811:1993)defined maintenance as:

the combination of all technical andadministrative actions, including supervisionactions, intended to retain an item in, or restore itto a state in which it can perform a requiredfunction.

Maintenance is a set of organised activities that

are carried out in order to keep an item in its bestoperational condition with minimum costacquired



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Maintenance Activities

Activities of maintenance function could be

either repair or replacement activities, which

are necessary for an item to reach its

acceptable productivity condition and these

activities, should be carried out with a

minimum possible cost.



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Basic Maintenance Activities

Cleaning

Checking

Repairing



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Developmentof

Maintenance

- Increased awareness

of:

- Environment

- Safety

- Quality

- Need for reliable

equipment.- Reduction in costs.

Maintenance History


Fix the equipment

when it breaks

-Term tero technology

introduced.

-Recognition of need topresent equipment

failures.

-Models for preventive

maintenance

developed.

Pre-World War II Post-World War II 1980 Onwards

Time

Maintenance History

(Adapted From Shenoy, Bhadury 1998)


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Maintenance Objectives

Maintenance objectives should be consistent

with and subordinate to production goals.

The relation between maintenance objectives

and production goals is reflected in the action

of keeping production machines and facilities

in the best possible condition.



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Maximising production or increasing facilitiesavailability at the lowest cost and at the highestquality and safety standards.

Reducing breakdowns and emergency shutdowns. Optimising resources utilisation.

Reducing downtime. Improving spares stock control

Improving equipment efficiency and reducing scraprate.

Minimising energy usage. Optimising the useful life of equipment.

Providing reliable cost and budgetary control.

Identifying and implementing cost reductions.



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PLANT

M

A

I

N

T

E

N

A

N

C

E

Reduce Breakdowns

Reduce Downtime

Improving Equipment

Efficiency

Improving Inventory

Control

Implementing CostReductionOptimising ResourcesUtilisation

Optimising Useful

Life of Equipment

Minimising Energy

Usage

Providing Budgetary

Control


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Types of Maintenance

Run to Failure Maintenance (RTF)

Preventive Maintenance (PM)

Corrective Maintenance (CM)

Improvement Maintenance (IM)

Predictive Maintenance (PDM)



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Run to Failure Maintenance

The required repair, replacement, or restore

action performed on a machine or a facility

after the occurrence of a failure in order to

bring this machine or facility to at least itsminimum acceptable condition.

It is the oldest type of maintenance.



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It is subdivided into two types:

Emergency maintenance: it is carried out as fastas possible in order to bring a failed machine orfacility to a safe and operationally efficientcondition.

Breakdown maintenance: it is performed afterthe occurrence of an advanced considered failure

for which advanced provision has been made inthe form of repair method, spares, materials,labour and equipment.



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Assignment No. 1

Describe run to failure disadvantages?



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Preventive Maintenance

It is a set of activities that are performed on

plant equipment, machinery, and systems

before the occurrence of a failure in order

to protect them and to prevent or eliminateany degradation in their operating conditions.



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Definition PM

British Standard 3811:1993 Glossary of terms

defined preventive maintenance as:

the maintenance carried out at predetermined

intervals or according to prescribed criteria

and intended to reduce the probability of

failure or the degradation of the functioning

and the effects limited.



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Types of Preventive

Maintenance Researchers subdivided preventive maintenance into

different kinds according to the nature of itsactivities:

Routine maintenance which includes thosemaintenance activities that are repetitive and periodicin nature such as lubrication, cleaning, and smalladjustment.

Running maintenance which includes thosemaintenance activities that are carried out while themachine or equipment is running and they representthose activities that are performed before the actualpreventive maintenance activities take place.



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Types of Preventive

Maintenance Opportunity maintenance which is a set of

maintenance activities that are performed on amachine or a facility when an unplanned opportunityexists during the period of performing plannedmaintenance activities to other machines or facilities.

Window maintenance which is a set of activities thatare carried out when a machine or equipment is notrequired for a definite period of time.

Shutdown preventive maintenance, which is a set ofpreventive maintenance activities that are carried outwhen the production line is in total stoppagesituation.



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Corrective Maintenance

In this type, actions such as repair, replacement, orrestore will be carried out after the occurrence of afailure in order to eliminate the source of thisfailure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary ofterms, corrective maintenance is defined as:

the maintenance carried out after recognition and

intended to put an item into a state in which it canperform a required function.



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Types of Maintenance

Remedial maintenance, which is a set of activitiesthat are performed to eliminate the source offailure without interrupting the continuity of theproduction process

Deferred maintenance, which is a set of correctivemaintenance activities that are not immediatelyinitiated after the occurrence of a failure but aredelayed in such a way that will not affect theproduction process.

Shutdown corrective maintenance, which is a setof corrective maintenance activities that areperformed when the production line is in totalstoppage situation.



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About Corrective Maintenance

The main objectives of corrective maintenanceare themaximisation of the effectiveness of all critical plantsystems, the elimination of breakdowns, theelimination of unnecessary repair, and the reductionof the deviations from optimum operating conditions.

The difference between corrective maintenance andpreventive maintenance is that for the correctivemaintenance, the failure should occur before anycorrective action is taken.

Corrective maintenance is different from run tofailure maintenance in that its activities are plannedand regularly taken out to keep plants machines andequipment in optimum operating condition.



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Performing Corrective

Maintenance The way to perform corrective maintenance activities

is by conducting four important steps:

1. Fault detection.

2. Fault isolation.3. Fault elimination.4. Verification of fault elimination.

In the fault elimination step several actions could betaken such as adjusting, aligning, calibrating,reworking, removing, replacing or renovation.



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Assignment No 2

Describe corrective maintenancedisadvantages!



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Predictive Maintenance

Predictive maintenance is a set of activities that detect

changes in the physical condition of equipment (signs of

failure) in order to carry out the appropriate maintenance

work for maximising the service life of equipment without

increasing the risk of failure.

It is classified into two kinds according to the methods of

detecting the signs of failure:

Condition-based predictive maintenance

Statistical-based predictive maintenance



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Predictive Maintenance

Condition-based predictive maintenancedepends on continuous or periodic conditionmonitoring equipment to detect the signs of

failure.

Statistical-based predictive maintenancedepends on statistical data from the meticulousrecording of the stoppages of the in-plant itemsand components in order to develop models forpredicting failures.



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Predictive & Preventive

The drawback of predictive maintenance is that it dependsheavily on information and the correct interpretation ofthe information.

Some researchers classified predictive maintenance as atype of preventive maintenance.

The main difference between preventive maintenanceand predictive maintenance is that predictivemaintenance uses monitoring the condition of machinesor equipment to determine the actual mean time tofailure whereas preventive maintenance depends onindustrial average life statistics.



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Maintenance Topology


MAINTENANCE

UNPLANNED

MAINTENANCE

(REACTIVE)

BREAKDOWNEMERGENCY

PLANNED

MAINTENANCE

(PROACTIVE)

CORRECTIVE

MAINTENANCE

REMEDIALDEFERRED

PREDECTIVE

MAINTENANCE

CONDITION -

BASED

STATISTICAL -

BASED

PREVENTIVE

MAINTENANCE

ROUTINERUNNING

DESIGN - OUTENGINEERING

SERVICES

WINDOW

IMPROVEMENT

MAINTENANCE

SHUTDOWN

CORRECTIVE

SHUTDOWN

PREVENTIVE

SHUTDOWN

IMPROVEMENT

Shutdown Maintenance

OPPORTU-

NITY


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Equipment Failure


Concept of Equipment failure (Kuhmonen, 1997)


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Kuliah 1 - Intro

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