1 Introduction

Reliability and Maintenance
Management
1
Introduction
SSIT-CASE
Fall 22
Engineered Objects
• Designed and built for specific functions

• Include a variety of products, plants, facilities and
infrastructures
• Have to function smoothly to ensure intended purpose
2
Engineered Objects
• Designed and built for specific functions

• Include a variety of products, plants, facilities and
infrastructures
• Have to function smoothly to ensure intended purpose
3
Engineered Objects Degrade and Eventually Fail
• Engineered objects are unreliable in the sense that they degrade with
age and/or usage and ultimately fail
• Failed = no longer able to carry out its intended function
• Failures occur in an uncertain manner and are influenced by several

factors such as design, manufacture/ construction, maintenance, and
operation (including human factor)
4
Consequences of Failure
• Consequence of a product failure may vary from mere inconvenience to

economic/ human loss
• Failure of an industrial plant or commercial facility may have major

economic consequences as it affects the delivery of goods and services
& eventually revenue loss. Some example for our of action engineering
objects:
‣ Large aircraft (A340 or Boeing 747) ~ $500,000/day;

‣ Dragline (used in open cut mining) ~ $1 million/day;
‣ A large manufacturer (for example, Toyota) ~ $1–2 millions/hour
5
Maintenance
Maintenance is the combination of all technical,

administrative, and managerial actions during the life
cycle of an item intended to retain it in, or restore it to,
a state in which it may perform the required function
Building in reliability is
Not having adequate costly and is constrained by
reliability is costlier due to the technical limits and economic
consequence of failures considerations
In a sense, maintenance may be
viewed as actions to
compensate for the unreliability
6
Aspects of Maintenance
• Technical (engineering, science, technology, etc.);
• Commercial (economics, legal, marketing, etc.);
• Management (from several different perspectives – manufacturer,

customer and maintenance service provider when maintenance is
outsourced)
Thus maintenance decisions need to be made

in a framework that takes into account these
issues from an overall business perspective
7
Maintenance from a Business Perspective
8
Classification of Engineered Objects
9
Assets and Systems
• The term asset is often used in the context of maintenance. Assets are
economic resources – tangible or intangible with a positive economic
value
• Business balance sheet records the monetary value of the assets owned
by the business. Tangible assets are written off against profits over their
anticipated lives by charging depreciation expenses
• The term system is used to denote a collection of interconnected

elements. Thus, a product, a plant, and an infrastructure may all be
viewed as a system
•
10
Performance of Engineered Objects
• Performance of engineered objects has many dimensions – and is best

characterized through measurable variables
• These measures may be divided broadly into two categories:
‣ Non-reliability performance
‣ Reliability performance measures
•
11
Non-reliability Performance Measures/ Indicators
• Include technical, operational, economic, environmental impact, etc.

Examples:
•
12
Reliability Performance Measures/ Indicators
• Include direct measures of reliability such as:

‣ Uptime/ Downtime
‣ SLA (Service Level Agreement)
‣ MTBF (Mean Time Between Failure), MTTF (Mean Time to Failure),
MTTR (Mean Time to Repair/ Resolve/ Replace)
‣ MTBSI (Mean Time Between Service Incidents), MRTS (Mean Time
to Restore Services), MTTD/I/K (Detect/ Identify/ Know)
13
Degradation of Performance
• Desired Performance is the starting point for the designing and

building/manufacturing of every engineered object
• The design process involves selecting components and materials to
ensure the desired performance for some nominal values (or ranges) for
usage and operating environment (E.g. 40k km for brake pads of
automatic transmission 1.5 ton vehicle operating in 20-30 C ambient,
40-50% humidity)
• The performance of the object degrades due to the degradation of the
material and components of the object. These are functions of age and/
or usage and are influenced by operating environment
14
Maintenance
• Maintenance involves actions to:

• Control or prevent the deterioration process leading to failure of an
engineered object (preventive maintenance)
• Restore the object to its operational state through corrective actions
after a failure (corrective maintenance)
15
Maintenance Costs
• Direct costs: These costs are incurred due to maintenance and repair
actions. Include cost of labor, material/ spare parts, contractors,
infrastructures used and taxes
• Indirect costs: These are costs resulting from the consequences
associated with failure or unplanned maintenance actions. Include
loss of revenue due to the production stops owing to maintenance and
repair actions, cost of accidents, demurrages, insurance policies etc.
The maintenance costs increase with time due

to the aging effect and increasing labor costs
16
Maintenance Costs
Think of your car’s

brake pads)
17
Maintenance Management
• Maintenance management
deals with maintenance-
related decision making at
the strategic, tactical, and
operational levels, and then
initiating actions to
implement the decisions
• Proper maintenance with
periodic in-service
inspections of an
engineered object has a
positive influence on the
technical state of the object
and may extend its lifetime
considerably 18
Role 0f Science & Technology in Maintenance Management
• An understanding of the
degradation process at the
component level is critical to
understanding the degradation
of the object
Technology has played an important role in assessing

the degradation through the use of sensors
19
Maintenance Evolution & Trends
• Mostly corrective maintenance till 1940s

• Operations Research (OR) in WW-II led to preventive maintenance at
component level and upwards
• Reliability Centred Maintenance (RCM) in 1970s, focusing on
sustained availability. RCM deals with optimization of preventive
maintenance activities considering failure consequences
• Total Productive Maintenance (TPM) evolved in Japan in 1970s,
focusing on involving all employees to ensure sustained availability of
the plant/ process
20
• Condition Based Maintenance (CBM) evolved in late 70s which

involves PM actions based on the condition (or level of degradation)
as opposed to age and/or usage. CBM leverages sensors technology
• Sensors getting smaller, more accurate and sophisticated
• ICT for generating and analyzing maintenance data for optimum
decisions
• Internet of Things (IoT) being used to continuously get real-time inputs
from sensors
21
• Management trends:
• Maintenance viewed as a function creating additional business value
• Shift from fail-and-fix to root cause elimination
• Shift from functional approach to process approach
• Risk-based maintenance focuses on reducing business risks
• Increased outsourcing to specialist organisations under SLAs
22
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Reliability and Maintenance

• Designed and built for specific functions

• Designed and built for specific functions

• Failed = no longer able to carry out its intended function

• Failures occur in an uncertain manner and are influenced by several

• Consequence of a product failure may vary from mere inconvenience to

• Failure of an industrial plant or commercial facility may have major

‣ Large aircraft (A340 or Boeing 747) ~ $500,000/day;

Maintenance is the combination of all technical,

• Technical (engineering, science, technology, etc.);

• Commercial (economics, legal, marketing, etc.);

• Management (from several different perspectives – manufacturer,

Thus maintenance decisions need to be made

• The term system is used to denote a collection of interconnected

• Performance of engineered objects has many dimensions – and is best

• These measures may be divided broadly into two categories:

• Include technical, operational, economic, environmental impact, etc.

• Include direct measures of reliability such as:

• Desired Performance is the starting point for the designing and

• Maintenance involves actions to:

The maintenance costs increase with time due

Think of your car’s

Technology has played an important role in assessing

• Mostly corrective maintenance till 1940s

• Condition Based Maintenance (CBM) evolved in late 70s which

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