RELIABILITY ENGINEERING

REVIEWER | AENG 417

-​ Depends on provided lifetime of the product

-​ Not reliable if it lasts before its lifetime
Topic Outline: 5.​ SPECIFIED CONDITIONS
●​ Introduction to maintenance and reliability -​ “Temperature” “speed” “pressure”
engineering -​ Will function under specific conditions
●​ Topic II
●​ Other components
1.​ Availability
INTRODUCTION
-​
TOPIC 2.​ Durability
SUB-TOPIC 3.​ Dependability
4.​ Quality over time

●​ A time dependent characteristic

-​ It can only be determined after an elapsed time but
can be predicted at any time.
-​ It is the probability that a product or service will
operate properly for a specified period of time (design
life) under the design operating conditions without
failure.
INTRODUCTION TO MAINTENANCE AND RELIABILITY
ENGINEERING DEVELOPMENT OF MAINTENANCE & RELIABILITY
​
1.​ First Generation Maintenance (Pre WW2)
DEFINITION OF RELIABILITY -​ Industry is not highly mechanized so
●​ Ability of an item to perform a required function under downtime is not particularly important.
given conditions for a given time interval. - IEC 60050 -​ Most equipment simple and over-designed
●​ The probability that an item will perform a required -​ Reliable and easy to repair.
function without failure under stated conditions for a -​ Eventually it just wore out.
stated period of time…” - Smith, D.J. (2005) -​ Only systematic maintenance required:
●​ Reliability is defined as the probability that a simple cleaning, servicing and lubrication.
product, system, or service will perform its intended -​ Philosophy: “Fix it when it breaks!”
function adequately for a specified period of time, or
will operate in a defined environment without 2.​ Second Generation Maintenance (WW2 - Mid 70s)
failure. -​ More mechanization and concern over
●​ The probability that an item/system will perform a downtime.
required function without failure under stated -​ Idea that failures could and should be
conditions for a stated period of time. prevented.
●​ Can also be expressed as the number of failures over a -​ Awareness of “burn-in” failure mode
period. -​ Burn in is when you subject a
●​ The most important components of this definition must be product into a test until it fails.
clearly understood to full know how reliability in a -​ Bath-tub curve
product or service is established: -​ Relationship between time and
failure
1.​ PROBABILITY -​ Visual Representation of failure and
-​ The likelihood of mission success time
-​ Chances
2.​ INTENDED FUNCTION
-​ Para saan ba?
-​ “To light” “to cut”
-​ Anything that can perform its intended
function is considered reliable
3.​ SATISFACTORY
-​ “Evaluation”
-​ Perform according to a specification, with an
acceptable degree of compliance
-​ Performing according to intended function
-​ Satisfaction to user
4.​ SPECIFIC PERIOD OF TIME -​
-​ Minutes, days, months, number of cycles -​ Increase in maintenance costs as a
-​ Time limit of a product proportion of total operating costs.
JFMN | MBCA | 1
 -​ Development of first planning and -​ Time-based maintenance
scheduling tools. -​ Condition-based maintenance
-​ Philosophy: Preventative overhauls
ROLE OF A MECHANIC AND ENGINEERS
3.​ Third Generation Maintenance (Mid 70s - Present)
-​ Aircraft data identifies 6 different failure ●​ To understand more about reliability engineering, it is
mode patterns. important to differentiate or describe the roles of
-​ Growth of mechanization and automation different departments working in the industry.
increases focus on plant availability and
reliability. Role of a Mechanic
-​ Effect of failures on Health, Safety &
Environment (HS&E) becomes important as ●​ Makes routine inspections, documents inspections,
regulations tighten. and repairs
-​ Cost of maintenance increases: Often 1st or ●​ Read and interpret maintenance manuals, service
2nd highest of all operating costs. bulletins and other specifications to determine or to
-​ New techniques become available to collect identify the feasibility and method of repairing or
data that would enable maintainers to: replacing malfunctioning or damage components is
-​ To predict failures - Predictive Maintenance one of the roles of a mechanic.
-​ Optimize maintenance decisions - Asset ●​ Performs scheduled maintenance
Management ●​ Runs ​ tests ​ after ​ making repairs or ​
-​ Believes in 0 Hour maintenance (Overhaul) performing maintenance
●​ Job duties may vary based on which part of the plane
is being worked on. A mechanic working on the
HOW RELIABILITY IS MEASURED exterior of a plane may be fixing a broken wing,
repairing paint or securing a door so it seals properly.
●​ The probability of an item that does not fail in a time A mechanic working on the engine may be changing
interval (0,t), (survival probability) the oil, replacing belts or repairing a broken part.
●​ Besides being measured as a probability, reliability ●​ An A&P mechanic must know and follow all
can be quantified via e.g. the following parameters or regulations set by the FAA. FAA regulations govern
metrics: the maintenance schedules, inspections, and repairs
-​ The mean number of failures in a given time made to airplanes. The FAA conducts regular checks
(failure rate) on equipment and ensures regulations are being met.
-​ Represented by λ (lambda)
-​ Mean time between failures (MTBF) – the Role of an Engineer (Design)
average time between successive failures.
-​ For repairable items ●​ They are the ones who are accessing the usability,
-​ Mean time to failure (MTTF) - the average environmental impact, and safety of an entire plant,
time that elapses until a failure occurs. also they modify existing products or processes to
-​ For non-repairable items increase efficiency and improve performance. (what
-​ Knowing when will the product lasts type of engineer is this)
●​ Develop new technological solutions
●​ Includes defining problems
OBJECTIVES OF RELIABILITY ENGINEERING
●​ Conducting and narrowing research
●​ To apply engineering knowledge and specialist ●​ Analyzing criteria
techniques to prevent or reduce the likelihood or ●​ Finding and analyzing solutions and making
frequency of failure. decisions.
●​ To identify and correct the causes of failures that do ●​ Testing aircraft to measure performance and identify
occur, despite the efforts to prevent them. areas for improvement is one of the roles of an
●​ To determine ways of coping with failures that do engineer.
occur, if their causes have not been corrected. ●​ Much of an engineer's time is spent on researching,
●​ To apply methods for estimating the likely reliability of locating, applying, and transferring information.
new designs, and for analyzing reliability data. Indeed, research suggests engineers spend 56% of
their time engaged in various information behaviors,
THEORY AND BASIC CONCEPTS including 14% actively searching for information.
●​ Engineers must weigh different design choices on
their merits and choose the solution that best matches
●​ Qualitative reliability
the requirements. Their crucial and unique task is to
-​ Fault Tree Analysis (FTA)
identify, understand, and interpret the constraints
-​ Failure Modes and Effects Analysis (FMEA),
on a design in order to produce a successful result.
-​ Failure Modes, Effects and Criticality
Analysis (FMECA)
●​ Quantitative reliability Role of an Engineer (Analysis)
-​ Statistical reliability
-​ Physics-based reliability ●​ Engineers apply techniques of engineering analysis in
●​ Maintenance testing, production, or maintenance.

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●​ Supervise production in factories and elsewhere TWO TYPES OF PREVENTIVE MAINTENANCE
●​ Determine the causes of a process failure
●​ Test output to maintain quality. a.​ Periodic ​ maintenance​ (Time Based
●​ Estimate the time and cost required to complete Maintenance - TBM)
projects.
Time-based maintenance consists of periodically
inspecting, servicing, and cleaning equipment and
TYPES OF MAINTENANCE replacing parts to prevent sudden failure and process
problems.
MAINTENANCE
- Most facilities have heating, cooling, and
ventilation system running throughout their
●​ The most misunderstood about maintenance is the building this system requires regular
true objective of the function. The objective of inspections and tune-ups to keep running at
maintenance is to maintain the assets of a company optimum efficiency much of the word is
so that they meet the reliability needs at an optimal simple such as keeping it clean and
cost. replacing air filters regularly.
●​ Its purpose is to ensure that all the machinery and
equipment required for production will operate at
optimal efficiency all the time.
●​ In Webster's dictionary, it defines maintenance as: ​ ●​ Predictive Maintenance
-​ To maintain
-​ Keep in Existing Condition This is a method in which the service life of an
-​ Preserve, Protect important part is predicted based on inspection or
-​ Keep from failure or Decline diagnosis, in order to use the parts to the limit of their
service life. Compared to periodic maintenance,
●​ The ultimate goal of maintenance is to provide predictive maintenance is condition-based
optimal reliability which meets the business maintenance. It manages trend values, by measuring
needs of the company. and analyzing data about deterioration and employs a
surveillance system, designed to monitor conditions
TYPES OF MAINTENANCE through an on-line system.

1.​ Breakdown Maintenance (Reactive) - A centrifugal pump motor in a cold

preparation plant is a vital asset of
-​ Its goal is to respond or fix something that has
day-to-day operations to avoid unscheduled
malfunctioned. It focuses on restoring broken or
downtime the maintenance team performed
faulted equipment to normal operating normal
monitoring of vibration with vibration meters
conditions if at all possible.
because it's a large piece of mechanical
-​ It means that people wait until the equipment fails to
equipment that performs heavy rotation.
repair it. Such a thing could be used when the
equipment failure does not significantly affect the
operation or production or generate any significant
loss other than the repair cost. Corrective maintenance
-​ It may be either planned or unplanned. Planned
Run-to-Failure (RTF) is associated with preventive ● Corrective maintenance is caring out after failure
maintenance. Unplanned - Corrective maintenance detection and it comes at restoring an asset to a
and reactive maintenance. Corrective maintenance is condition in which it can perform its intended
associated with preventive maintenance of both function while predictive maintenance tends to
types. include direct measurement of the item.
-​ Can be used when an equipment failure does not
significantly affect the operation/ production/ generate ● It improves equipment and its components so
significant loss other than repair cost. that preventive maintenance can be carried out
-​ Pag may sira! reliably. Equipment with design weaknesses must
be redesigned to improve reliability or improve
maintainability.
2.​ Preventive Maintenance (Pro - active)
-​ It is a daily maintenance ( cleaning, inspection, oiling, ➔ An example is while performing regular plumbing
and re-tightening ), designed to retain the healthy maintenance and inspections the crew notices that the water
condition of equipment and prevent failure through the pressure in the back half of the building is low, further checks
prevention of deterioration, periodic inspection, or found that a pipe has become clogged by mineral deposits.
equipment condition diagnosis, to measure The team gets to work on an emergency repair right away.
deterioration. It is further divided into periodic Associated with preventive maintenance. Corrective
maintenance and predictive maintenance. Just like maintenance tasks can be both planned and unplanned.
human life is extended by preventive medicine, the Performs when there is: a detection during monitoring,
equipment service life can be prolonged by doing uncovers ​ potential ​ fault ​ during
preventive maintenance.
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inspection, ​ and breakdown.

Maintenance Prevention

- It indicates the design of a new piece of

equipment. Weaknesses of current machines are
sufficiently studied (on-site information leading to
failure prevention, easier maintenance and
prevention of defects, safety, and ease of
manufacturing ) and are incorporated before
commissioning new equipment.

- It is a concept of ensuring reliability and

maintainability of manufacturing the product by
providing various information collected during
actual operations to their prototype.

- It is applied in the development phase of an item

or product to examine and improve the qualities
and specifications of performance.

This was done during the design phase.

Zero Hours Maintenance (Overhauls)

The set of tasks whose goal is to review the equipment at
scheduled intervals before any failure appears, either when the
reliability of the equipment has decreased considerably so it is
risky to make forecasts of production capacity. This review is
based on leaving the equipment to zero hours of operation,
that is, as if the equipment were new. These reviews will
replace or repair all items subject to wear. The aim is to
ensure, with high probability, a good working time fixed in
advance.

Associated with preventive maintenance and corrective

maintenance.

It is the process of removing the powerplant from the aircraft

and transporting it to the shop to make the new or
reconditioned parts in doing reassembly and reinstallation,
testing, and completing the paper works.

The present generation also believes in the philosophy of

doing zero-hour maintenance to make the product reach its
optimal reliability.