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CHAPTER 3 INDUSTRIAL CONSERVATION AND RELIABILLITY. 42
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CHAPTER 3
INDUSTRIAL CONSERVATION AND RELIABILLITY
Its development started about 1958.
CHAPTER’S OBJECTIVES
At the end of this chapter, the reader will:
Understand the concept of industry and its mission in the human context
Demonstrate the importance of industrial products to sustain Earth’s habitat
Will explain what is Availability in industry
Interpret the meaning of industrial Effectiveness
Understand the concept of “product’s useful life time” (PULT).
Distinguish between the meanings of Reliability and Dependability.
Explain what are the Systems in Series, Parallel and Series-parallel.
Describe RCM’S general evolution in industry.
Identify the 6 “Failure Patterns” existing in a system.
Interpret the meaning of “Continuous Improvement”.
Illustrate what the 4 “Conservation Strategies” consist of.
Make generalizations about RCMII development.
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Contents
3.1 INTRODUCTION ......................................................................................................................... 44
3.1.1 Industry and its mission. ........................................................................................................ 44
3.1.2 Industry and its product. ....................................................................................................... 44
3.1.3 The product and its market. ................................................................................................... 46
3.2 INDUSTRIAL AVAILABILITY ....................................................................................................... 46
3.2.1 Industrial Maintainability ............................................................................................................ 47
3.2.3 Industrial Reliability. .................................................................................................................. 48
3.2.3 Industrial Logistics. ................................................................................................................... 49
3.3 INDUSTRIAL EFFECTIVENESS. ................................................................................................ 49
3.3.1 The integration of an industrial company. ................................................................................. 50
3.3.2 Product useful life time (PULT). ............................................................................................... 52
3.4 INDUSTRIAL RELIABILITY. ........................................................................................................ 57
3.4.1 Dependability for a system in series Dss .................................................................................. 59
3.4.2 Reliability for a system in parallel Rsp....................................................................................... 60
3.4.3 Dependability of a system in series-parallel Dssp. .................................................................... 60
3.4.4 Summary................................................................................................................................... 64
3.4.5 Service is first. ........................................................................................................................... 64
3.4.6 Maintenance for a vital service. ................................................................................................. 65
3.5 CONSERVATION CENTERED IN RCMII. ................................................................................... 66
3.5.1 Failure patterns ......................................................................................................................... 69
3.5.2 The industrial “Maintenance” Manual. ....................................................................................... 72
3.5.3 Continuous improvement team. ................................................................................................ 72
3.5.4 Product’s conservation status. .................................................................................................. 74
3.5.5 Conservation General Strategies. ............................................................................................. 75
3.5.5.1 Preservation General Strategies ............................................................................................ 75
3.5.5.2 Maintenance General Strategies ............................................................................................ 76
3.6 RCMII IN CONSERVATION. ........................................................................................................ 78
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3.1 INTRODUCTION
Current knowledge about maintenance, even though important, will be tremendously enhanced when
we become conscious at World level that we are mistaken calling Industrial Maintenance what truly is
Industrial Conservation. At present, this change is a real Challenge that demands scientifically
prepared minds in this subject. We only need to study and work to reach our highest possible
summit. In the way, with our own efforts, we will find the knowledge we need to improve, at World
level, not only the different existing industries, but also our habitat. This book will help you to find the
path to change and to know, in depth, about industrial conservation and its importance for industry all
over the world.
Let us remember that in subtopic 2.4 we defined Industrial Conservation as “human action in a
system, that through the application of scientific and technical knowledge, contributes to the optimum
use of existing resources in a human habitat thus favoring man’s and his ecosystem integral
development. Industrial conservation’s study is divided in two large branches, one is Preservation
which refers to the material part of the system and Maintenance which is related to the service
provided by the matter.”
The material we have seen so far has provided the required foundations for readers and scholar to
understand Maintenance as a branch of Industrial Conservation. The following chapters of this book
are structured with this focus on mind.
3.1.1 Industry and its mission.
By definition, industry is the group of operations and processes that have the objective of
transforming raw material into manufactured products that, when operating, will form a
system or human satisfactor.
The establishment of industry was initiated by men to obtain food and clothes to be able to
survive. However, industry has grown exponentially to such a degree that it destroys human
habitat at the same rate and velocity. Thus, it is vital to humanity to pay special attention to
industry’s development
3.1.2 Industry and its product.
Let us analyze the concept of product under the following Premises:
A product is any item capable of providing a human satisfactor.
A satisfactor is a complete system which when functioning, provides a service.
A satisfactor is comprised of matter, intelligently interlinked in such a way, that when
it is functioning it provides a service with a predetermined quality
A functioning product becomes a system providing satisfaction to its user (figure 3.1)
The satisfactors reason for being is the quality of the service they provide to their
final consumer.
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Industrial effectiveness is found in the equilibrium between the quality of the matter
integrating a product and the quality of the service it provides during its useful life
time.
Figure 3.1 Example of different products working as systems
Therefore, the tasks we must perform for the care of both are of two types: matter must be
cleaned, protected, not over charge it; in other words, it must be Preserved to obtain a good
output and durability in good condition during its useful life time (PULT). In regard to the
service this matter provides, we must make sure to Maintain it within the expected quality
parameters, and if for some reason it is not achieved, we will need to strengthen or change
the arrangement of the matter that comprises the product. We should emphasize that we are
referring to the products manufactured by our company and not to the machines that produce
them.
If a satisfactor has been appropriately designed, all its components fulfill a function and thus,
are all necessary. Then, as long as the needs that created them do not change, the
conservation tasks will be focused on guaranteeing the appropriate operation of said
satisfactor, preserving its matter and maintaining the quality of its service. It provides and the
user expects, all of which should happen during all of the product useful life time (PULT).
Idle ProductFunctioning System = Satisfactor
Working product Service obtained
hot
Battery Battery
Idle ProductFunctioning System = Satisfactor
Working product Service obtained
Cold
20°C 0°CProducto ocioso
Sistema funcionando = Satisfactor
Producto trabajando Servicio obtenido
Unclean H2O Unclean H2O Distilled H2O
Product in operation = System = Satisfactor
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3.1.3 The product and its market.
The product must be designed to function as a satisfactor within the market to which it is
directed. This is the reason why any company, before designing its product, must define the
market it wants to target since there is an indeterminate number of markets. This variability
stems from the fact that markets are comprised by people.
Let us remember that every person is different due to his/her individual characteristics (age,
socioeconomic, intellectual, cultural, temperamental levels, etc.). That is, we are continually
undergoing transformation throughout our lives. Despite these differences, human beings
share a common denominator: our gregarious nature which propels us to seek approval from
others regarding our thoughts and actions. We all have physical and psychic needs to be
satisfied in order to survive in this world. So, ever since we are born we search for the things
that satisfy our needs or whishes. We are pleased when our search ends with a satisfactor
that provides the quality that we want and can afford to pay. This, in fact, is precisely what
causes the establishment of markets that conform to the different human expectations,
which, in turn, define the quality, cost, and type of products or services that are required . It
has also generated the rapid growth of high “Availability” industries
3.2 INDUSTRIAL AVAILABILITY
Industrial Availability can be defined as the ability of an industry to keep performing a specific function
within predetermined quantity, quality, cost, and time parameters.
The most important attribute for a manufacturing company is its capital assets high Availability, which
means that they must fulfill three characteristics:
1. That they can easily be protected or restored so that they can continue to perform their
required functions (MAINTAINABILITY).
2. That the company, as a moral person, has achieved in its markets, the reputation of being
reliable (RELIABILITY).
3. That its markets be served strategically and logically so that its products be present at the
right place, with the proper quality, quantity, and time (LOGISTICS).
Graphically, we can illustrate Industrial Availability in the following way:
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Figure 3.2 Pillars of Industrial Availability
Let us analyze each part of Industrial Availability.
3.2.1 Industrial Maintainability
Maintainability is defined as the simplicity an item has to be protected or restored in order to
be able to perform its required functions. The above leads us to think that an item has good
maintainability the faster and easier we can successfully perform programmed conservation
or restoration so that it continues its predetermined performance. Maintainability refers to the
industry’s capital assets and it depends on many factors such as the asset’s design and
manufacture, the quality of the materials comprising it, the installing personnel’s ability, the
asset’s level of preservation, maintenance, and operation, the work space provided for its
operation and conservation, its ease of access, the availability of spare parts and appropriate
test equipments, the ease to disassemble, assemble, and change spare parts, environment,
etcetera.
The asset’s design must cover maintainability criteria as follows:
That it consists of very inexpensive and easily interchangeable modules to allow the
“use and discard” concept.
That its parts and modules be standardized to allow minimization and exchange
quickly and easily.
That the tools required to deal with the asset be ordinary, not specialized..
That the connectors joining the different asset’s modules be done in such a way that
they cannot be exchanged by mistake.
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That the asset’s operation and conservation tasks can be performed without
endangering persons or vitally important assets.
That the asset has brackets, handles, supports, and holders that allow the whole or
its parts to be easily moved and to lean them without danger while it is attended.
That the asset has diagnostic indicators or self-diagnosis modules that enable to
rapidly identify a cause for failure.
That the asset has an appropriate system to identify modules and test points, easy to
see and interpret.
There are many other criteria regarding this topic. However, the criteria we have already
covered are enough for us to understand that it is in our hands to significantly improve, with
our will and skill, the efficiency of a company’s resources, by increasing their maintainability.
For example, if our company is going to purchase a new machine, we can help providing our
point of view about the maintainability criteria the machine should fulfill, choose the place
where the machine should be installed, and during its installation, supervise that its
maintainability be safeguarded; also, with the aid of the supplier, we can design the
conservation strategies for the machine, combining the suppliers recommendations with the
advantages and disadvantages of the machine’s installation site.
Moreover, if we see an equipment’s frequent failure, which is caused by the same set of
elements, we can research the feasibility of making a module for such set so that we can
have one or more of these modules available to install at the appropriate time. This way, the
next failure, it would be easier and quicker to change the module, than the tasks that were
previously performed..
3.2.3 Industrial Reliability.
Industrial Reliability is the degree of trust given to an industry by its clients or market.
Ever since the initial idea of creating a Business, it is necessary to consider its reliability. At
present, Business firms, regardless of their type or size, are immersed in an environment of
highly competitive markets. Thus, the behavior of each firm is severely judged.
In the 60’s, Business planning began to be done more carefully, process which was called
“Long term planning”. By the middle of the 70’s, the development of “Strategic planning”
started. All these trends were the result of the need to support businesses reputations. The
above has resulted in modern Management using methods that have been proved successful
for developing “Life Plans” for physical quality persons, as can be confirmed in internet. If we
analyze any type of important company’s “Business plan”, we will find that it includes a
“Vision”, a “Mission”, its “General Objectives”, and many other criteria that are important
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enough to be currently studied by true modern scientists. Among these scientists, we can
mention Stephen R. Covey, “The 7 Habits of Highly Effective People”, Nathaniel Branden,
“How to Improve your Self-Esteem”, Howard Gardner, “The five minds of the future”, Daniel
Goleman, “Emotional Intelligence”, Luis Castañeda “A Life Plan for Young People”, to cite a
few. We consider this topic so important that we will study it in subtopic 7.5.
3.2.3 Industrial Logistics.
Logistics, from industrial conservation perspective, is the administrative labor required to
strategically see to the flow and storage of raw materials, work in process, finished goods,
etcetera, to take them from their point of origin to the appropriate places with the quality,
quantity, and timeliness required by the user. In other words, it is the appropriate
Management of a supply chain.
Industrial logistics originated from American war industry, around the same time that
Productive Maintenance (PM) was developed, during World War II (1939-1945). The
products manufactured by the war industry (arms, ammunitions, explosives, war vehicles,
etc.), as well as their destination, were vital for the war effort, which created a strong
relationship between the military allies and the American industrialists. Due to the experience
and profound knowledge of the military, it was decided to use military logistics to distribute
war products to the places they were needed the most. The industrialists learned and later
adopted this system.
3.3 INDUSTRIAL EFFECTIVENESS.
Industrial Effectiveness is the achievement of the expected effect in terms of quantity, time, place and
form.
An industry so considered is deemed as highly productive. However, to reach this status, it is
necessary that it is continuously reaching its planned objectives, that it obtain results, that it be
efficacious, and at the same time, that it uses its resources appropriately, that it be efficient. Thus, we
have the industrial quality parameters:
.
Industrial Effectiveness = Efficaciousness + Efficiency
Efficacy is the optimum achievement of the time, place, and form objectives.
Efficiency is the optimum use fo resources to achieve the objectives.
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We need to consider that one can be efficient without being efficacious, and that one can also be
efficacious without being efficient. We have witnessed the failure of many industries even though they
had great material and technical resources both in quantity and quality. They did not reach their
objectives because as work tools, they did not consistently obtained the expected results, or
misapplied or misused their resources; in other words, they were inefficacious, or inefficient, or both.
That is, they were not effective.
3.3.1 The integration of an industrial company.
The reason for the existence of an industry is to obtain profits, and its general objective is to
become a sustainable and competitive moral being; in an Effective industry, constantly
growing, in spite of the instability that will appear with time. Let us study figures 2.9 and 2.10,
and use this criteria to build Figure 3.3.
Figure 3.3 Industrial Effectiveness
If we want to create a successful company, we must, from its beginning, plan it so that it is
effective. to better understand This concept, we can consider a figure comprised of the main
subsystems that are involved in its effectiveness such as the “Efficacious work teams”
subsystem and the “Efficient product” subsystem. (See Figure 3.4).
The subsystems “Efficacious work teams” are comprised by our operators with their
machines purchased from our suppliers, which are, in turn, responsible for the machines’
fulfillment of the warranty they gave us. That warranty is supported by the Product useful life
time pattern (PULT), which we studied and accepted when we purchased the machine.
The subsystem “Efficient products” refers to our products which we have designed and
manufactured with our work teams, and therefore, only our company has the ability to make
the product useful life time pattern (PULT) to be delivered to our clients.
Efficacious work team
+Efficient product for its user
Industrial Effectiveness
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The product useful life time (PULT) is the pattern used to measure the product’s efficiency
during its warranty time, which is the next topic we will study in depth.
We can now imagine an industry as a system composed by two or more important
subsystems, immersed in the same symbiotic environment, as shown in figure 3.4. The
inputs are taken from other companies and the satisfactors produced are made available to
other companies that coincide in the same environment.
Figure 3.4 Industry as a System of subsystems
This order of ideas allows us to clearly see the following:
Premises:
The concept of industrial conservation and its taxonomy is clarified since with our
work teams we are producing ecologic Systems (Efficient products) for which
conservation tasks are oriented to preserve matter and maintain quality of the
service it provides (see Figure 2.19).
The operation of the “Subsystem Work Teams” is provided by the “Capital Assets”,
which are the goods and Rights with Money value, which are property of the
company, such as machinery, buildings, equipment, land, etc., and they are used
exclusively in the generation of income or profit.
The operation of the complete “Industrial System” is derived from the benefit from or
sale of satisfactors. The above urges us to accept that the paramount objective of
any industry is that its products be true satisfactors for the markets for which they
have been designed. In summary, the user of our product must be satisfied.
Each industry must deliver to its clients their products useful life time (PULT). This clarifies
the extent of the warranty and the conservation conditions to which the items considered as
work capital will be subjected to. It is the foundation for the advantage of purchasing the
product. Similarly, we must also deliver to our clients the PULT for each of our products,
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which explains our warranty, commitment, and care that must be given to our product for it to
work as a quality system.
The effectiveness of an industry is based on the “efficient products subsystem” and not on
the “work Teams”. We would like to stress that we are talking about the products
manufactured by our company and not to the machines which produce them. This clarifies
the “Industrial Effectiveness Principle” which refers to the “Equilibrium between the quality of
the matter that comprises the product and the quality of the service it provides as a system
during its useful life cycle”.
Figure 3.5 Industrial Effectiveness Principle.
3.3.2 Product useful life time (PULT).
Generally stated, a product’s useful life time is a managerial tool used to measure the
effectiveness of a product when it is functioning as a system.
The capture of clients among competing companies starts with market research to know in
depth the needs to cover in regard to the type and quality the clients expect from a product.,
thus achieving the appropriate design. From it, said satisfactor will include, under certain
conditions stipulated by the manufacturer, a useful life time of “T” number of hours, days,
months, or years operating as an effective system. This way, the buyer will know with
certainty if the item he is buying (capital asset) is the correct item to install in his business.
From this point of view, we can derive the premise that the manufacturer is the only one that
can know the true useful life time for his products since he knows the quality of the matter
and technology applied in it manufacturing.
At present, there is a classification and order for the useful life time of a product, shown in
figure 3.6, which we will analyze next. .
Matter quality Service Quality
Satisfactor
Products functioning = SATISFACTOR
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Figure 3.6 Product’s Useful Life Time Taxonomy
Let us study each of its parts in a logical and sequential way:
PRODUCTS’S USEFUL LIFE TIME
Useful life time. It refers to the time
elapsing from the new product being
satisfactorily installed (commissioning)
in its working place until the end of the
manufacturer’s warranty. During this
time, said product only has two status,
Active or Inactive (Figure 3.7).
Figure 3.7
Active time is the time considered as necessary for
the resource’s functioning in the company (Figure
3.8).
Inactive time. It is the time that for planned reasons, is
used to do conservation work on the resource or for it
to be retired because it is no longer useful to the
company (Figure 3.11).
TIEMPO ACTIVO
PRODUCT USEFUL LIFE TIME
ACTIVE TIME INACTIVE TIME
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PRODUCT’S USEFUL LIFE TIME
ACTIVE TIME INACTIVE TIME
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Active time is the time considered
necessary for the resource to operate
in the company. We divide it in
Operation time, when the item is
functioning well, and Down time, when
the item has reached a failure, (Figure
3.8).
Figure 3.8
Operation time. It refers to the time the resource is
functioning within the service quality specified limits
and it is the reason for the existence for said
resource. (Figure 3.9)
Down time. It is when, due to unplanned causes, the
resource ceases to function within the specified limits,
resulting in losses due to waste, resource’s excessive
wear, and inability to be used. (Figure 3.10).
OPERATION TIME
Operation time. It is when the resource is
working within the stipulated limits of
service quality and is the reason for being
of said resource. It is divided in
preparation, warm up, and operation, as
shown below:
Figure 3.9
Preparation time. It is the time used by the operator
before starting work to obtain all that is necessary and
to verify that the resource can function as a system.
Warm up time. It is the time needed to take the
resource to its normal operation level.
Work time. It is when the resource is functioning as a
system and providing the service within the expected
quality (study Figures 3.9 y 3.12).
DOWN TIME
Down time. It is when, due to unplanned
reasons, the resource ceases to function
within stipulated limits causing losses due
to waste, excessive resource wear,
product reprocess, and inability to use. It
Organization time. It is the time required to notify the
contingency personnel about the resources (human,
physical, and technical) that will be needed, and for
them to arrive to the site to attend to the emergency.
Diagnosis time. It is the time used to verify the
ACTIVE TIME
OPERATION TIME DOWN TIME
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is divided in organization, diagnosis,
enablement, repair, adjustment,
calibration, verification, recording and
statistics.
Figure 3.10
resource’s malfunctioning, its temperature, vibration,
noise, and oil levels, energy input and output,
indicators readings, etc., until the failure cause is
identified and to determine the necessary corrective
actions.
Enablement time. Is the time used to obtain the
necessary parts or spares (tools, test equipment,
material, etcetera).
Repair time. It is used to replace or repair the worn out
resource parts to attain its functioning within stipulated
service quality limits.
Adjustments and Calibration time. It is the time used to
perform the necessary tests and adjustments to
achieve that the resource within the expected service
quality range.
Verification time. It is used to start the resource’s
operation and decide if it can be put into service again.
Recording and statistics time. It is the time used to
record the type of work done, date, hour, and time
spent, and all the information deemed useful to back
up future analysis and diagnosis.
IDLE TIME
Idle time. It is the time planned for
conservation tasks to be done to the
resource, or for the time to take the
resource out of production because it is
no longer useful to the company. It is
divided in idle time and storage time.
Idle time. The time needed to execute the preventive
conservation recommended by the manufacturer. It is
divided in planning, routines, overhaul, and statistics,
as explained below:
Time for planning. It is the time needed to get
to the resource site, observe and record the
behavior of sensors and gauges, and to do the
planning required (Deming Circle) to determine
the corresponding routines and work orders.
Routines and work orders time. It is the time
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Figure 3.11
needed to execute the work covered by the
corresponding planning. It includes its
preparation and the required tests to verify that
the expected results were achieved.
Overhaul time. It is the time needed to perform
in depth maintenance work, usually covered by
a special work order. It includes the
preparation time and the testing required to
verify the work was performed correctly.
Statistics. It is the time used to record the work
orders and routines, once they have been
finished.
At last, we have storage time:
Storage time. It is the time that the equipment is stored
because the company no longer requires its services.
This time ends with the sale of the resource or the
manufacturer’s warranty.
The study of previous chapters has given us new points of view about biology, ecology,
Systems theory, etc. and we have very infrequently used them to attend to the repair of our
machines. But now we have more logical and scientific concepts, and from this perspective,
we will analyze the “Resource’s Useful Life Time” that we have developed.
Let us imagine a time line depicting the useful life of a product, from its birth to its death
(Figure 3.12). We will use the product “AC Generator” to illustrate this concept. Every day, its
operator puts it to work as a system, for which he prepares it, turns it on until the start up is
done, and puts it to work during the 8 hours of his shift. At the end of his shift, he turns it off,
and the system is interrupted, so that the generator, depending on circumstances, will occupy
a position on the time line at Idle, Down, or Storage. Usually, these events are repeated daily
until the useful life time warranted by the manufacturer is finished.
INACTIVE TIME
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Figure 3.12.
Let us now think about an “Ideal manufacturing machine” with a 100% reliability, and thus
utopian; that is, it does not need the works mentioned in the Down, Idle, and Storage times. It
does not even require a preparation or a start up time to begin functioning appropriately; it
only needs to be started and it will provide the expected product throughout its useful life
time. This is a very important concept and as such, it should compel us to take it as our ideal
pattern, so that we can try to achieve 100% reliability for both our manufacturing machines as
well as the products they manufacture. That is, the “work” life time should be much longer
than the other times and the latter should be minimized. Thus, we should keep in mind the
following premises:
Operation time is the reason for being of a product and it exists when the product
becomes a system so ideally we should work to minimize the preparation and warm
up times
The time included in Down, Idle, and Storage are not useful for the product but are
necessary and are always present, so we need to study them to minimize them.
3.4 INDUSTRIAL RELIABILITY.
Reliability is the probability that a component, product, or system, works to perform a specific task, in
given conditions, during a predetermined time. Reliability is defined with a value. Reliability’s ideal
value is 100%, therefore, when we state that an item is 100% reliable, we are saying that there is no
doubt that said item will work without failing during that time.
Thus we have:
Ideal Reliability = 100%
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PRODUCT’S USEFUL LIFE TIME VIRTUAL IMAGE
DOWNIDLE
TIME LINE
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In practical terms, it does not exist since there is always the possibility of random failures to
occur, which we call unreliability and define it as the probability that an item does fail. Within
this order of ideas, we have:
Item’s reliability = Ideal Reliability – Item’s unreliability
If we use “R” for Reliability and “U” for Unreliability, we will have:
Item’s Reliability = R = 100% – U
Therefore, an item’s Reliability will never reach 100%
Since the reliability concept is applicable to each of the parts that comprise a product, for all practical
purposes, when undertaking conservation tasks, we should always consider that our main focus
should be centered on the product that our industry is manufacturing for its quality will enable
us to increase our market share.
When a product is used in combination with others to initiate a joint activity, they become a system
and keep a precise behavior in accordance to their position in reference to the set. There are
three general operating positions in which the parts of a system can be placed: in series, in parallel,
or in series-parallel. Let us see what each of these positions involves
System in series. Items are installed one following the next. In this arrangement, if any of the
equipments ceases to operate, the system is immediately lost and with it, its service.
Figure 3.13 Items connected in series.
System in parallel, Items are installed one next to the other. With this arrangement, the three items
provide the same service so that if any of them ceases to function the service will continue to be
provided without loss of quality until the last item fails in which case the system and the
service will fail.
Figure 3.14 Items connected in parallel.
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System in series-parallel. Its reliability depends on the interrelation of the systems that comprise it,
so it is necessary to first calculate the reliability of the system in parallel and then the reliability
of the system in series. For our purposes, we will use the system in series parallel shown in Figure
3.15 which consists of three items installed in series and one in parallel to support the lowest
reliability item. With this arrangement, all four provide a very high reliability and the service will
continue to be provided without quality loss until the last item fails thus failing the system and
with it, the service.
Figure 3.15 Items connected in series-parallel
Let us analyze it:
We will do the math required to calculate the three systems. For our examples, we will use the
following reliability and unreliability values for the four equipments considered above.
Reliability I = RI = 0.96 Unreliability I 0.04
Reliability II = RII = 0.62 Unreliability II 0.38
Reliability III = RIII =0.97 Unreliability III 0.03
Reliability IV = RIV = 0.98 Unreliability IV 0.02
3.4.1 Dependability for a system in series Dss
The reliability of a system in series, (Figure 13) results from the product of the reliability of its
parts.
According to this statement, we only have to multiply the reliabilities to obtain the following
result.
where:
From which we can infer that the reliability of a system in series is lower than the
lowest reliability of any of its parts.
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3.4.2 Reliability for a system in parallel Rsp
The reliability of a system in parallel is equal to the product of the unreliabilities of its parts
subtracted from ideal reliability. Taking figure 3.14 as an example, we have:
The conclusion we reach is that the Reliability of a system in parallel is higher than the
highest Reliability for any of its parts
3.4.3 Dependability of a system in series-parallel Dssp.
The Reliability for a system in series parallel depends on the interrelation of the
Systems that comprise it, therefore, according to what we have learned from the last two
subsystems, and using the reliability and unreliability data to solve these cases, we only need
to first calculate the reliability of the system in parallel and then the reliability in series
for the set.
In order to make our explanation easier, let us consider equipments II and IV as only one
equipment “A” connected in series with equipments I and III (Figure 16) which reliabilities we
already know so that we only need to calculate equipment A’s reliability, comprised by
equipments II and III in parallel:
Reliability A = ideal reliability – (U II X U IV) = 100% - (0.38 X 0.02) = 1 - 0.008 = 0.992
Figure 3.16.
We have turned this group of two Components in parallel into one which reliability is
0.99%, and which we will call Equipment A, placing it between equipments I and III which
thus results in only one system in series, as shown in figure 3.17
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Figure 3.17 Resulting system in series.
From the above, we now only need to calculate the resulting system in series to find out the
reliability of a system in series parallel. Thus we have:
Reliability for the resulting system in series Rsrs = 0.96 x 0.992 x 0.97 = 0.924
As the equipment operates, the reliability of its parts decreases, which in turn increases the
probability that it fails. The preventive conservation routines are meant to diagnose and
restore the lost reliability. If we analyze a machine’s or equipment’s interior, we will see that is
composed of systems, which are made up of subsystems, the subsystems by modules, the
modules by components, and these by elements. All of them are involved in one way or
another in providing a product: They behave as “links” in regard to providing a product,
sometimes in series, others in parallel, or in occasion, in series-parallel. Our labor will be to
analyze these ”links” in order to find those below the expected reliability, observing the type
and frequency of their failures to place another link in parallel, or strengthening it, or
substituting it for better technology to increase its reliability. This analysis must be done again
for subsystems, and so on. We can better appreciate this topic through the following
anecdote.
“In our experience in phone Communications during the 1960’s, to transmit signals from one
place to another instead of physical lines over poles, we used “Microwave relay Stations”
which were usually located at a mountain, 10 to 20 kilometers from the nearest town, with
very well trained personnel living in these buildings. Even so, we could not guarantee a
continuous service since correcting immediately a failure interrupting the service was, for all
purposes, impossible. So in the stations we considered as high risk, and to insure phone
service to users, we would place redundant machines to increase the reliability of the system.
Later, the supplier provided equipments with the redundancy in duplicated modules. Thus, if
the equipment was damaged, the waiting redundant module automatically replaced the
damaged module and in milliseconds, the system was working appropriately. The technician
just and only had to exchange the damaged module and send it to the manufacturer to be
replaced. At present, this process is continually improving, and it is very common in modern
equipment.”
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From the above we can deduce that to achieve a high reliability in our area of competence,
we need not duplicate complete machines but only that part or parts that have a low
reliability.
This is the true labor of those of us dedicated to conservation, to be constantly analyzing the
defects or failures in our assets and industrial products to determine if there is a decrease
in the systems’, subsystems’, modules’ and elements’ reliability.
From what we have already seen, we can apply our knowledge about reliability in a practical
way by doing the following exercises.
Exercise 1:
Let us consider a Communications net between ends A and B, like the one shown below to calculate:
Undependability for each component (Ua, Ub, Uc, Ud, Ue).
Total dependability for a system in series (Dss).
Figure 3.18 System in series.
The total dependability for this system in series is : Dss = 0.44, please calculate it.
Exercise 2:
This system in parallel with equipments a, b, c, and d lacks dependability (D) or undependability (U)
data, please calculate:
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Figure 3.19 System in parallel
Exercise 3:
Calculate total dependability for this system in series parallel.
Let us try to improve the system in series, so we note that the components that highly decrease the
dependability are the copper cables. Fortunately for us, there are optic fiber cables we can use.
Figure 3.20 System in series parallel
Total dependability for this system in series parallel is Dssp = 0.945.
Now try to calculate it.
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3.4.4 Summary.
Up to this point we have analyzed two of the most important of our assets attributes:
Maintainability and Dependability. If we make a comparison, we will realize that a high quality
item will exhibit these attributes as shown in figure 3.21.
Figure 3.21 Criteria for maintainability and dependability
With this knowledge about dependability and remembering figure 2.11, we can observe that
our products, in the hands of users, become functioning Systems (satisfactors) which leads
us to Conserve the system, Preserve the product, and Maintain the service, and that the
specific case for Dependability is directed to the care of the service provided by our product
3.4.5 Service is first.
When an equipment provides a service classified as vital or important, it should never be
allowed to operate outside of its predetermined parameters for any reason. However, there is
always the possibility that in spite of all our care and effort, there may be a contingency which
may cause a service failure.
To minimize the negative impact of contingencies, we must analyze in depth the equipment
to locate the parts or subparts with low dependability and restore them, or it that is not
possible, to think about a replacement or the installation in parallel of an element, part,
subpart, or complete system.
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When a service is classified as vital we must insure that the system that provides it will have
enough redundancies in parallel to increase dependability and decrease the possibility of a
failure.
It is important to emphasize that from the care required by the matter that comprises the
system and the service it provides, Service is first.
3.4.6 Maintenance for a vital service.
Let us take as an example a factory that has evaluated the importance of its electricity supply
in reference to the negative impact caused by a failure in said supply. Therefore, they
determined that electricity transfer to a specific group of machines and offices should be
considered vital. Thus, they proceeded to prepare a “Contingency Plan” similar to the one we
will see in topic 8.6.
Figure 3.22 shows how, through the use of a system comprised of three subsystems, they
seek at any cost to avoid loosing a service classified as vital. The three subsystems are
working at the same time, but subsystem number 1 was initially providing the service. When
an anomaly occurred, the subsystem sent an “outside of service quality” signal to the
automatic change box, which switched to subsystem 2. It continued providing the service
until it was affected by another anomaly, so subsystem 3 took over in order not to loose the
service. If this latter system suffers another anomaly, the service is interrupted..
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Figure 3.22 System to insure a vital service
The reliability of a system comprised of several subsystems keeps its value even if all the
subsystems, but one fail. When this happens, we must restore the affected system or
systems as soon as possible. The above illustrates that by applying the industrial
conservation theory, we are caring more for the service than for the matter since we are
discarding the latter (malfunctioning subsystem) and using a new subsystem in order to
maintain the service within the specified parameters.
3.5 CONSERVATION CENTERED IN RCMII.
Remembering the 60’s, those of us working in conservation tasks for automatic phone switchboards
received verbal and written instructions from our providers that the installed equipment would provide
the service guaranteed by the manufacturer if we performed the following tasks:
Changing the used parts by new parts with the frequency indicated by the manufacturer.
Changing the broken or worn out parts after a routine check.
Changing the damaged parts as required by corrective maintenance.
Protect the equipment with the appropriate environment in the installation site.
In regard to our experience in the phone industry, we had, among other parts in our central phone
boards, “selectors” composed of a stainless steel sheet measuring 40 X 40 centimeters. There were
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gears, springs, and relievers installed over the selectors, which, operating electromagnetically,
moved an arm to an exact position to enable to connect a couple of wires with another wire. So, and
with a specific quantity of these “selectors” we would build a physical road of conduits from one
telephone to another in any part in the world.
The “maintenance” routine required that we had skilled personnel, adept at cleaning the “selectors”
every six months, using grease removers, special oils, test equipment, and new parts to do
replacements. However, in spite of these thorough repairs, and the high costs incurred, some of
these equipments suffered a greater number of failures than before the cleaning and adjustments
routine. Our clients were constantly upset, and we thought that our personnel were not careful
enough and that the changes of parts should be more frequent; but, despite everything, the failures,
and thus the costs continued increasing.
Later on, we replaced the “maintenance” routines by the use of reliability criteria. The central phone
boards were now comprised of transistors, and advanced technology chips, which thus turned these
parts into high reliability components. This change improved considerably the quality of the service
provided to the user.
Something similar was happening in commercial airlines. Air accident statistics .were high so they
were forced to join their efforts to find solutions to catastrophic events. It was 1950 when the
American civil aviation industry, taking advantage of the use of applied statistics, mainly to the
behavior of airplanes, achieved the first advances in this topic. At this time, Weibull analysis was
having very good results in estimating the probability of a machine failure, both with assumed and
real data.
The above led the airplane manufacturers to assemble a group of experts to study in depth these
events and to seek how to provide an optimum conservation for commercial airplanes. Thus, they
organized work groups comprised of specialists from the airplane manufacturers, from commercial
airlines, and the American Air Force, which constituted the Maintenance Steering Groups (MSG).
Sponsored by the American Air Transport Association, these groups researched catastrophic events
during twenty years, as well as the actions and solutions performed to solve or alleviate the
problems. This research resulted in the MSG – 1 Guide, and the Maintenance Evaluation and
Program Development Manual. These documents were presented in 1968
In 1970, at the request of the American government, a document, “Reliability Centered Maintenance,
written by Stanley Nowlan, and Howard Heap, was released. This document deals with the planning
for maintenance programs for manufacturers and airlines. It is called MSG–2, and has had very good
results to date.
The last version of the above mentioned document, MSG-3, was released in 1978, with such great
success that it has only required sporadic revisions, done, the first in 1988, the second in 1993, the
third in 2001, and the fourth in 2004. These revisions are due to all kinds of changes naturally
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occurring in the airplane environment. MSG–3 is still the basis of maintenance planning systems for
different items, such as military weaponry, ships, industries, auto fleets, etc.
In regard to the decrease in catastrophic airplane accidents, we must be grateful for the application of
RCM, worldwide, because otherwise, given the evolution of civil aeronautics, the studies show that
we would have had two catastrophic airplane accidents every 20 to 25 days.
In 1980, John Moubray and Associates, with Stanley Nowlan (co-author of the MSG-2 and MSG-3)
as an advisor, was one of the most advanced companies in the study and application of the RCM.
They succeeded in applying RCM to a large range of industries. The above made possible the
development and usage of RCM-2, which focuses on the reliability and safety of items, and adapts it
to the true needs of the manufacturer or company using it.
Let us consider any airplane as a system composed of Man/Machine; that is, the airplane as a
machine is a handled by a crew and their joint effort provides a satisfactor to their users. On the other
hand, there have been many companies interested in applying this system to other industries. These
companies, among them John Moubray and Associates, confirmed that the RCM did not produce the
same results as in the aeronautical industry. This group, consulting with Stanley Nowlan, worked
initially with RCM in the mining and manufacturing industries in South Africa, and later migrated to the
United Kingdom. From there, they expanded their activities to cover the application of RCM to almost
all fields of organized human endeavors, in over 44 countries. Moubray and Associates use Nowlan’s
work as their basis, while keeping their original focus in equipment reliability and safety, they added
environmental topics to the decision taking process, classified the ways in which the operations of the
equipment should be defined, and developed precise rules to select “maintenance” tasks, as well as
their application frequency. They also incorporated directly quantitative risk criteria to a group of
intervals for failure patterns search tasks.
Their RCM version is known currently as RCM2.
Next figure gives us an overview about man’s tendencies to develop “maintenance” for his habitat
and work tools, from where he has had to evolve towards conservation.
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Figure 3.23 Evolution toward the Industrial Conservation.
3.5.1 Failure patterns
Around 1950, the industry’s economy revolved increasingly around the “Maintenance” cost of
the machines. This led to program maintenance with a certain frequency through the change
or repair of items’ parts, since it was believed that usage was a determinant of their useful
life. So, they started applying to physical assets, the same criteria used in studying the life of
peoples, as can be seen in figure 3.24 which shows the Deivis curve. .
Imagine persons comprising any nation. This
conglomerate is composed by three regions: the first
region is the early life, formed by children; the second, is
the useful life region, composed of young and mature
people; the third is the exhaustion region integrated by the
elderly. If we draw a graphic, with real data, we can
confirm that this is the way the life of the people behaves.
That is, at birth, and for some time afterward, we have a
greater risk of dying; as time goes by, it is more probable
that we experience death through sporadic dying of
people in our age range; but death rate increases with
age. This is a rather close description of the pattern of
failures for a nation. It is represented by the Deivis curve
or bath tub curve.
Figure 3.24 Bath tub curve
The frequent use of the bath tub curve, since approximately 1950 on, created in the industrial
environment the mistaken idea that the time of usage of a physical asset was the only factor
determining its good performance. This led to “over- maintenance”, increasing costs and
decreasing the quality of the product, which was actually opposite to expected results. The
above resulted in the commercial aviation studies, in the United States (from ATA) as already
Early life Useful life Exhaustion
TIME
Failures
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mentioned. Besides the introduction of the MSG-3, other important findings were the
discovery of six failure patterns. (See figure 3.25).
Incr
easi
ng C
ompl
exity
Pattern “A” (Deivis curve)
Let us remember that this curve has
two failure regions, the early life,
and the exhaustion, while its useful
life remains with a constant failure
rate. It has been verified that only 4
% of the items behaves according to
this pattern The failure rate
registered during their useful life is
random
Pattern B
This pattern shows no early life, but
rather starts with useful life with a
constant rate of failures, until it
reaches its exhaustion stage. Only 2
% of the items behaves according to
this pattern. The failure rate through
its useful life has a random nature
Pattern C
This pattern does not have early life
nor exhaustion stages, and all its
useful life, it behaves with a slowly
increasing failure rate leading to
exhaustion. Only 5 % of the items
portrays this pattern of behavior.
The failure rate throughout their
useful life is random.
Pattern D
This pattern shows an inverse early
life and has a constant failure rate
throughout its useful life until its end.
7% of the items exhibit this
behavior. The failure rate during its
useful life is random.
TIEMPO
FALLAS
TIME
FAILURES
TIME
FAILURES
TIME
FAILURES
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Pattern E
This pattern displays no early life or
exhaustion regions, and during its
useful life, its failure rate shows a
slight tendency to increase to
exhaustion. 14 % of the items
exhibit this pattern of behavior. The
failure rate throughout its useful life
is random.
Pattern F
In this pattern we can see that it
does have an early life region and
that its useful life shows a constant
failure rate until its end. 68 % of the
items behave according to this
pattern. The failure rate is random
throughout its useful life
Figure 3.25 MSG-3 Failure Patterns in mechanical and electric Items used in airplanes.
.
Based on these results, it is obvious that in terms of both dependability and cost, our
conservation processes must be integrated considering that the failure rates are due to
random events and not by the aging or time of usage of an item, especially for complex
machines.
To have a clearer idea, let us imagine that we have purchased the latest car model of a well
known manufacturer. We will soon feel secure, trusting, and satisfied with the machine, and
we will note many features while driving it. If we open the hood, we will be very favorably
impressed with the motor. It is formed, as the rest of the vehicle, by thousands of parts, each
in its exact place, and many of them also composed of subparts that aid in its operation.
Each of these myriad items has its own failure pattern. They behave as links of a so called
virtual chain net that have been arranged in series, in parallel, or in series-parallel to achieve
our satisfaction. We obviously need this machine to be serviced by experts in shops with
appropriate diagnostic tools, and following the strict routines established by the manufacturer.
If we can get the above within our location, it will insure that the expectations promised by the
manufacturer will be fulfilled. Undoubtedly, we will also verify that the machine in question
requires an owner, an operator, a shop, and mechanics, all according to its quality.
TIME
FAILURES
TIME
FAILURES
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3.5.2 The industrial “Maintenance” Manual.
For the moment, let us not talk anymore about man made systems (equipment, machines,
etc.) and consider the solar system, which is the habitat of millions of species, including
intelligent life, in order to know how it is protected (See topics 2.2 and 2.3). First, we see that
we are within a cyclic system and that to better understand it, we have developed a
science known as ecology which studies the relationships of live beings among themselves
and with their environment. In sociological terms, ecology studies the relation between
human groups and their environment, both physical and social. Its main objective is the
conservation of human habitat, that is, its preservation and maintenance. Our problem is
that nature has not given us a detailed manual or instructive to do it. So we have to carefully
observe its functioning and on this basis, “edit our own manuals”, and whenever
possible, apply it to man made systems so that we act in harmony with nature. We have
learned most of our activities to protect our habitat in the last 120,000 years taking care of
“things” rather than “ecological systems”. Therefore, we have written for our machines the
instructions or “Maintenance Manuals” that although they help, are not appropriate for
caring for the life system on earth, as we shall see later.
Let us return to our topic regarding man made systems:
The normal operation of any system tends to deteriorate its physical state. For the system to
fulfill its expected useful life time, it is necessary to think carefully how it must be protected.
In regard to industry, the life cycle preservation plan for its product (satisfactor) is studied,
written, and delivered by the manufacturer and we know it as the maintenance manual and
it includes the “conservation tactics and strategy” which are a great help for both the
product’s manufacturer and the user. This interaction between the producer and the user
causes a synergy, a continuous improvement process for both firms, when they are involved
in two types of activities which we always need to keep in mind: the “strategic” and the
“tactical”. Let us analyze their meaning and interrelated functioning
.
3.5.3 Continuous improvement team.
The strategic function is developed at any moment in time to achieve future results. The
tactical function is developed to attain immediate results. For a soccer team, let us see the
following matrix as an example:
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CONTINUOUS IMPROVEMENT TEAM
Strategic function Tactical function
The training of the players, the plays previous
analysis on the blackboard, the planning of how,
where, when, and with whom will the team be
playing; that is, all that is focused to future
results but that occupies our present time is a
strategic function.
The activities during the game, like the touch of
the ball between the players, the exchange of
players due to fatigue, or convenience, or any
other reason, the signals given by the team
players among themselves, the assistants, the
trainer; that is, all those activities that as soon as
they are executed, generate a result are
classified as tactical activities.
In a similar way, in a company, the leaders at any level, be they CEO’s, managers,
supervisors, department heads, etc., must accustom themselves to think in terms of these
two approaches to improve the management of the human, physical, and technical resources
they oversee, whether their activities are directed to take a decision, solve a critical situation,
or analyze a possible problem. We always need to keep in mind the strategy and the tactics
of any task. For example, if a part is required urgently, the first step is to obtain the part
(tactical action) as soon as possible, but immediately after, we need to analyze and
implement whatever is necessary to avoid this problem in the future (strategic action). In our
milieu, we generally use only tactical actions which cause problems to become repetitive,
time is wasted, and productivity decreased.
We need to be aware that a good leader plans and acts, in the first place strategically to
analyze and solve any situation he is dealing with, and afterwards, based on his strategic
plan, he programs his tactical activities. We need to emphasize that only in real emergency
situations should one proceed immediately with tactical plans and actions. However, when
the emergency is over, one must think how to avoid this emergency situation from happening
again and plan whatever is necessary to achieve it (strategic action). With any kind of
planning (strategy) or programming (tactics) we should always think of the future, seeking
the largest quantity of information as to how that future will be and how it will intervene in the
actions we want to perform
We should be aware that our thoughts will jump from one level to a different one of the topic
we are analyzing, and we may even talk about other topics looking for practical solutions.
That is the mechanics of human thought, and we must consciously use it during planning or
programming.
It is our belief that a successful company should be designed in such a way that during its
normal operation, it achieves continuous improvement (Kaisen). The above is achieved when
we make sure that our tactical tasks are derived from and give feedback to a strategy.
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We need to always keep in mind that “Every tactic must come from a strategy and every
strategy is improved through the results of a good tactic.”
3.5.4 Product’s conservation status.
From topic 2.4, let us remember from Industrial Conservation and its taxonomy that it is
divided into the branches Preservation (of the matter that comprises the product) and
Maintenance (of the quality of the service provided by the product). It is important that we
note the difference between them since both are applicable to any resource existing in
Nature. Thus, a machine can be subjected to cleaning, oiling, repairs, or painting. All these
tasks can be classified as Preservation tasks if they are done to avoid damage to the
machine. However, they will be described as Maintenance if their objective is that the
machine continues to provide a service with a specified quality. In other words, while
Preservation is focused on the material care of the resource, Maintenance is oriented to
caring for the quality of the service provided by the resource.
The relative situation of a working product (system) regarding its status norm only has two
behavior forms, called status and which are known as:
If the satisfactor is within norm = Preventive status
If the satisfactor is outsider of norm = Corrective status
Preventive status Corrective status
Accumulated dirt that
does not damage
matter.
Accumulated dirt that
damages matter.
Accumulated dirt that
does not affect service.
Accumulated dirt that
affects service (failure)
Figure 3.26 Conservation Status
For each status, there are lists, reports, and plans for conservation tasks that must be
performed during a satisfactor’s complete life cycle. These are called “General Conservation
Strategies” which we will see next.
.
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3.5.5 Conservation General Strategies.
Conservation General Strategies are the tasks included in what we currently know as the
maintenance manual that the manufacturer delivers with its product. This manual explains
the activities required during the useful life time, when the product is at any of its four
conservation status. There are four types of conservation strategies.
Figure 3.27 Conservation General Strategies
3.5.5.1 Preservation General Strategies
All work, done in systems with the objective of caring for the matter that comprise them, is
called Preservation work, and has a corrective and a preventive status, as shown below:
Figure 3.28 Preservation General Strategies
General Conservation
Strategies
a) General Preservation
Strategies
I. Corrective Preservation
Strategies
II. Preventive Preservation
Strategies
b) General Maintenance
Strategies
III. Corrective Maintenance
Strategies
IV. Preventive Maintenance
Strategies
a) Preservation General
Strategies
I. Preventive Preservation
Strategies
II. Corrective Preservation
Strategies
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At present, most companies have system or resources that require many manual
preservation tasks. Although with the development of electronics and computer science,
automation has reached such levels in some organizations that these manual tasks are now
minimal. So, we can say that personnel has evolved form craftsman to technical craftsman,
and now to technician specialized in the Maintainability and Reliability analysis software used
for the systems to be Conserved.
From the above we can conclude that there are two types of Preservation: preventive and
corrective.
Preservation General Strategies.
1.- Preventive Preservation: Deals with protection tasks performed to the matter of a resource
to avoid attacks by harmful agents.
For example, paint a newly installed hopper or a new satisfactor
2.- Corrective Preservation: Refers to the remedial tasks that must be performed to the matter
of a resource when it has degenerated or has been attacked by
harmful agents.
For example, paint a Hopper after it was repaired.
.
Figure 3.29 Preventive and Corrective Preservation
In this subtopic we analyzed only the first conservation branch, that is, the care of the matter
that forms a system. We will now study the second branch which refers to the service that
matter provides.
3.5.5.2 Maintenance General Strategies
Any type of work in systems aimed at continuing to provide or provide again a service with an
expected quality are maintenance tasks; that is, they are focused on attending to the service
and not on the matter that provides the service. The typical maintenance work is the search
and strengthening of the weakest links of a Satisfactor’s service chain.
CHAPTER 3 INDUSTRIAL CONSERVATION AND RELIABILLITY. 77
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Figure 3.30 Maintenance General Strategies
There are only four types of Maintenance, Preventive, Predictive, Corrective, and Detection.
Co
rrec
tive
Mai
nte
nan
ce
stra
teg
ies
3.- Corrective Maintenance.
(failure repairs)
Inspection, control, and restoration services for an item
working as a system in order to prevent, detect, or
correct failures..
4.- Detection Maintenance.
(search fro hidden flaws)
Inspection, control, preservation, and restoration
services for an item that works as a closed system, with
the purpose of preventing, detecting, or correcting
mistakes or defects that can cause failures
Figure 3.31 The four types of Maintenance strategies
In the preventive maintenance strategies, if a satisfactor or system is operating within the
control limits, it is constantly informing us, through its closed systems (controls for
temperature, pressure, voltage, etc.) about the degree of deviation against the expected
optimum, so that we may start any required actions to correct any abnormality before it
b) General Maintenance
Strategies
IV. Preventive Maintenance
Strategies
Preventive Maintenance
Predictive Maintenance
III.Corrective Maintenance
Strategies
Corrective Maintenance
Detection Maintenance.
Maintenance general strategies
Pre
ven
tive
Mai
nte
nan
ce
stra
teg
ies.
1.- Preventive Maintenance.
(replacement or programmed
repair)
Set of operations and required care restoring or
replacing an item or its components, at programmed
intervals so that a system can continue to work properly
and does not reach failure
2.- Predictive maintenance.
(search for defects and
errors)
Follow up services of the wear of one or more
components of a vital system through symptomatic
analysis, statistical estimates, or through electronic
means with the objective of proceeding on basis of the
condition found.
CHAPTER 3 INDUSTRIAL CONSERVATION AND RELIABILLITY. 78
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reaches a failure level, which would force us to work as established in the preventive
strategies.
Figure 3.26 shows the usual way in which abnormalities occur which lead to preventive or
prediction maintenance.
Status How did we find out about the defect or
error?
Strategy to apply
Preventive
The system showed diverse and sporadic
abnormalities, but did not loose its performance
quality.
Preventive
Maintenance
We used specialized software, prediction
statistics or both which advised us how soon
would the failure occur
Prediction
Maintenance
Figure 3.32 Preventive maintenance strategies.
Corrective maintenance strategies have their own way of expression according to the type of
system, open or closed, to which they are applied. For example, for closed systems, since
they are hermetic and do not inform the system to which they belong what is happening
within them, like temperature, or pressure controls, etc, which have stuck indicators but show
a good reading. For these cases, a thorough investigation or detection is required. (See table
3.27).
Status How did we find out about the failure? Strategy to apply
Corrective
The CA voltmeter showed the delivery tension
outside of tolerance limits.
Corrective Maintenance
It was necessary to detect it through a physical
inspection of the voltmeter.
Detection Maintenance
Figure 3.33. Corrective maintenance strategies.
3.6 RCMII IN CONSERVATION.
John Moubray mentions in his book “Maintenance centered on Reliability”, that in 1950, at world
level, commercial aviation had registered over 60 catastrophic accidents per million flights, and that
66 % of these were caused by equipment failure, in spite of over-maintenance given to the airplanes,
which, sometimes, was also the cause of failures. The seriousness of the problem resulted in highly
trained experts analyzing the causes of these failures. Among these Experts, the Swedish PhD
Walodi Weibull (1877-1979) presented, in 1951, to the American Society of Mechanical Engineers
CHAPTER 3 INDUSTRIAL CONSERVATION AND RELIABILLITY. 79
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(ASME), seven case studies using the “Weibull Distribution”. This technique is used to find the
distribution of failures in a system we want to control.
USA’s Air Transport Association studied this problem during two decades since the loss of human life
in the accidents was very painful and important to the future of aerial navigation at world level.
Therefore, they decided to sponsor groups of specialists which were called Maintenance Steering
Groups (MSG).
Since 1951, Japanese Genichi Taguchi (1924) introduced a methodology to apply statistics to
improve the quality of products since its design, “Robust Design”. This resulted in improvements in
the production process, delivery to clients, and two important aspects of the product, such as its
maintainability and its reliability, characteristics.
In 1961, the Japanese engineer Shigeo Shingo (1909-1990) started developing the Baka-Yoke
Systems, (fool proof), name which was later changed to the present known Poka-Yoke (error proof).
The Poka-Yoke Systems detect events through switches sensitive to light, to pressure, photoelectric,
thermostats, etc. They intervene in a process regulation through an alarm for the operator, or
automatically stopping the process, or both.
We can verify that all these ideas and works that started developing since 1950,have achieved an
increase in human safety in the use of dangerous products (airplanes, transports, tools, ocean
vessels, arms etcetera). They have also aided in clarifying the industrial conservation philosophy.
It is our opinion that the British scientist, John Moubray, with his RCMII
development, has provided revolutionary ideas for applying reliability concepts in the
manufacturing industry. These ideas have served as basis for the advanced thought
we have seen in the last four or five years. We have seen that the most outstanding
strategy, due its versatility and quality assurance for the items where it is applied, is
the Prediction strategy, as we will see next.
The strategy currently called prediction maintenance uses two branches of human knowledge,
Prediction and Condition. Let us analyze each of them.
a) Prediction: It is the action or effect of predicting, with scientific basis, something that will
happen during an item’s operation.
b) Condition: are the events that intervene, positively or negatively, on the prediction about
the operation of an item..
Remember that the search for an equilibrium between Action and ¨Reaction in a system is done
through the application of Prediction Maintenance. This provides the opportunity of performing any
type of Preventive Maintenance, with which we have a closer contact and is based in having
redundant equipment or circuits, appropriate alarm systems, and advanced technology test tools This
is the most reliable of the maintenance strategies.
John Mitchell Moubray
(1949 – 2004)
John Mitchell Moubray
(1949 – 2004)
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To understand the scope of Predictive Maintenance we must keep in mind the following glossary:
GLOSSARY
Conservation. To insure the physical preservation of a system and to maintain the quality of
its product during its useful life cycle.
Defect. Disorder in a system caused by its comprising matter, and influenced by its
environment.
Error. Disorder in a system caused involuntarily by man.
Entropy. Measurement of the disorder in a system.
Status. A system’s relative situation in reference to the quality of the service it is
providing.
Preventive status. When the system is fulfilling its design parameters.
Corrective status. When a system reaches failure.
Failure. The end of the ability of a system to perform a required function, causing
economic losses..
Catastrophic failure. The end of the ability of a system to perform a required function which causes
the loss of human life.
Homeostasis.
Peculiar characteristic of self regulated systems which consists of being able
to keep on a dynamic equilibrium status, within certain limits, changing some
internal structure parameters.
Complaint. Claim against supplier done by users of a system which does not meet
promised quality.
We can historically verify the spectacular increase in the importance of industrial machinery
throughout the years since in 1880, only 10% of production was machine manufactured, and the
remaining 90% was obtained through labor. Currently over 95% of production is done through
machines, which are increasingly more rapid and exact. To attend modern machinery, we are
required to use many diagnosis devices, and analysis techniques for vibrations, temperature,
continuous and alternating current, friction, balancing, etcetera. We need experts in the usage of
diagnosis tools, as well as in the operation and functioning of the machines and systems to be taken
care of. We should always keep in mind that all of this should be based in the employment of the
correct maintenance strategy, which according to what we have analyzed so far, it is predictive
maintenance strategy. This strategy is currently used every day in first level industries with the
application of the criteria used by RCMII (Reliability Centered Maintenance).