Chapter - Five: Reliability, Availability and Maintainability

Chapter - Five
Reliability ,Availability
and
Maintainability
Maintenance and Reliability
 The objective of maintenance and
reliability is to maintain the capability of
the system while controlling costs
 Maintenance is all activities involved in
keeping a system’s equipment in working
order
 Reliability is the probability that a machine
will function properly for a specified time
What is Reliability?
• Reliability is the probability that a product, service, or
part will perform as intended(without failure) for a
specified period of time under normal conditions.
R(t) = 1- F(t).
• Failure – the termination of the ability of an item to
perform its required function.
• Failures may be sudden (non-predictable) or gradual

(predictable). They may also be partial or complete
16-3
Product Failure Rate (FR)
is the frequency with which an
engineered system or component fails,
expressed in failures per unit of time
FR(%) = Number of failures x 100%

Number of units tested
Number of failures
FR(N) = Number of unit-hours of operating time
Mean time between failures is a reliability term

used to provide the amount of failures
per million hours for a product. 1
MTBF = FR(N)
Failure Rate Example
20 air conditioning units designed for use in
Garment washing section operated for 1,000 hours
One failed after 200 hours and one after 600 hours
2
FR(%) = 20(100( %) = 10%
2
FR(N) = = .000106 failure/unit hr
20,000 - 1,200
1
MTBF = = 9,434 hrs
.000106
Cont.d
 In the nineteenth and early twentieth-century:
• Designs were less severely constrained by the cost and

schedule of delivery time pressures.
• Components were individually fabricated and there was

no mass production and standardization of parts
• Thus, in many cases, high levels of reliability were

achieved as a result of over-design
16-6
Cont.d
 Nowadays, modern technology has developed capacity to
design and manufacture equipment and systems of greater
capital cost, sophistication, complexity, and capacity.
• The consequences of low availability and high

maintenance cost of such systems led to the desire for:
- high reliability,
- high maintainability, and

- low mean time to support (easily maintainable).
16-7
• observed reliability is empirically defined as the ratio of items
which perform their function for the stated period to the total
number in the sample
• For example, a product with a 90 percent reliability has a 90

percent chance of functioning as intended. Or,
the probability that the product will fail is 1 - .90 = .10, or 10

percent. This also means that 1 out of 10 products will not
function as expected.
16-8
RELIABILITY SYSTEM
16-9
Series system
 The reliability of a product is a direct function of
the reliability of its component parts.
• The probability that a garment will perform as

intended is, therefore, a function of the
reliabilities of its fabric, sewing thread, buttons,
zip and other parts.
16-10
Rs = (R1) (R2) (R3) . . . (Rn)
where Rs = reliability of the product or system.
R1... n = reliability of components 1 through

n
• As the reliability value of a component is most of

the time less than one, the reliability of a system
is lower than that of individual components.
• This is because all the components in a series

must function for the product to work.
16-11
• If only one component doesn’t work, the entire
product doesn’t work.
• The more components a product has, the lower

its reliability.
• For example, a system with five components in

series, each with a reliability of .90, has a
reliability of only (.90)(.90)(.90)(.90)(.90) =
0.59.
16-12
Parallel system
Rs = Reliability of 1st Component + (Reliability of 2nd

Component * Probability of needing 2nd Component)
Where: Probability of needing 2nd Component = probability

of the 1st component failing
16-13
EXAMPLE
16-14
16-15
Sol/n
16-16
Reliability can be increased by:
 Reducing Complexity: The fewer component parts and

the fewer types of material involved, the greater is the
likelihood of a reliable item.
• Modern equipment, so often condemned for its

unreliability, is frequently composed of thousands of
component parts all of which interact within various
tolerances
 Duplication/replication: the use of additional, redundant,

parts 16-17
Cont.d
• But it adds capital cost, weight, Spares, Space, preventive

maintenance and power consumption
 Excess strength: Deliberate design to withstand stresses

higher than are anticipated will reduce failure rates.
• Again this also incurs additional costs
16-18
 Quality and reliability are interrelated:
• A system cannot be reliable if it does not have high

quality. Is it true always? Likewise,
• a system cannot be of high quality if it is not reliable.
 Their goal is the same – to achieve customer satisfaction
• If a system is unreliable, it is unpredictable and if it is

unpredictable, it is not of high quality.
16-19
AVAILABILITY
Availability tells information about how you use time
A = Uptime/(Uptime + Downtime) .
 Mean Time Between Failures(MTBF) – Applies to repairable items.
 Mean Time To Failure(MTTF) – Applies to non-repairable items. Both of

these terms indicate the average time an item is expected to function
before failure.
 MTTR: Mean Time to Repair is the time needed to repair a failed item
 Availability = MTBF
____________
MTBF + MTTR
16-20
Example
20 air conditioning units designed for use in
Garment washing section operated for 1,000 hours
One failed after 200 hours and one after 600 hours
if the MTTR of the two fail component is 20 hr calculate
the availability of the system
2
FR(%) = 20(100
( %) = 10%
2
FR(N) =
20,000 - 1,200
= .000106 failure/unit hr = 9434 hr
9434hr +20hr
1
MTBF = = 9,434 hrs =0.9978
.000106
MAINTAINABILITY
The probability that a system or system element can be repaired in a
defined environment within a specified period of time. Increased
maintainability implies shorter repair times
Two kinds:
Preventive maintainability
Corrective maintainability
16-22
Reliability and Cost
• There are three separate cost factors related to the
reliability of an item throughout its life –
- Design & Development cost
- Production cost
- Maintenance & Repair cost
16-23
Cont.d
16-24

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What are the main factors that affect reliability?

What are the main factors that affect reliability?

What is the difference between reliability and maintainability?

What is the difference between reliability and maintainability?

Chapter - Five

specified period of time under normal conditions.

• Failures may be sudden (non-predictable) or gradual

FR(%) = Number of failures x 100%

Mean time between failures is a reliability term

 In the nineteenth and early twentieth-century:

• Designs were less severely constrained by the cost and

• Components were individually fabricated and there was

• Thus, in many cases, high levels of reliability were

• The consequences of low availability and high

- high maintainability, and

• For example, a product with a 90 percent reliability has a 90

the probability that the product will fail is 1 - .90 = .10, or 10

• The probability that a garment will perform as

where Rs = reliability of the product or system.

R1... n = reliability of components 1 through

• As the reliability value of a component is most of

• This is because all the components in a series

• The more components a product has, the lower

• For example, a system with five components in

Rs = Reliability of 1st Component + (Reliability of 2nd

Where: Probability of needing 2nd Component = probability

 Reducing Complexity: The fewer component parts and

• Modern equipment, so often condemned for its

 Duplication/replication: the use of additional, redundant,

• But it adds capital cost, weight, Spares, Space, preventive

 Excess strength: Deliberate design to withstand stresses

• Again this also incurs additional costs

• A system cannot be reliable if it does not have high

• a system cannot be of high quality if it is not reliable.

 Their goal is the same – to achieve customer satisfaction

• If a system is unreliable, it is unpredictable and if it is

 Mean Time Between Failures(MTBF) – Applies to repairable items.

 Mean Time To Failure(MTTF) – Applies to non-repairable items. Both of

- Design & Development cost

- Maintenance & Repair cost

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