Maintainability, Availability, And

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MAINTAINABILITY, AVAILABILITY, AND

OPERATIONAL READINESS

ENGINEERING HANDBOOK

VOLUME 1

TABLE OF CONTENTS

CHAPTER 1- MAINTAINABILITY ENGINEERING ...... ………… 1
1.1- HANDBOOK OBJECTIVES ...... …… 1
1.2- RELIABILITY AND MAINTAINABILITY

ENGINEERING OBJECTIVES AND

BENEFITS ...... … 4
1.3- BENEFITS DERIVED FROM THE

IMPLEMENTATION OF RELIABILITY AND

MAINTAINABILITY ENGINEERING ...... ………… 8

CHAPTER 2- SYSTEM EFFECTIVENESS AND
RELIABILITY ENGINEERING

CONCEPTS ...... ……… 21

2.1- SYSTEM EFFECTIVENESS ...... ………... 21

2.2- A COMPREHENSIVE DEFINITION

OF RELIABILITY ...... …….. 26
2.3- A QUANTIFICATION OF SYSTEM

EFFECTIVENESS ...... ….. 27

2.4- A COMPREHENSIVE DEFINITION OF

MAINTAINABILITY ...... ….. 30
2.5- WHAT IS RELIABILITY ENGINEERING? ...... …………... 30
2.6- WHY RELIABILITY ENGINEERING? ...... ………… 31

2.7- WHAT ARE THE PRACTICAL
APPLICATIONS OF RELIABILITY AND

MAINTAINABILITY ENGINEERING? ...... ………… 32

CHAPTER 3- MAINTENANCE ...... ……… 37
3.1- MAINTENANCE DEFINED ...... ……… 37
3.2- PREVENTIVE MAINTENANCE ...... ……….. 37
3.3- CORRECTIVE MAINTENANCE ...... ……….. 40
3.4- OPERATING TIME AND DOWNTIME

CATEGORIES ...... …… 41

3.5- MAINTENANCE PERSONNEL FACTORS

AND COSTS ...... ……. 44
3.6- MAINTENANCE PERSONNEL

SAFETY FACTORS ...... 45
3.7- MAINTENANCE SUPPORT FACILITIES

AND EQUIPMENT ...... 46

CHAPTER 4- MAINTAINABILITY DESIGN CRITERIA ...... …….. 49

CHAPTER 5- DOWNTIME DISTRIBUTIONS

AND MAINTAINABILITY

ENGINEERING FUNCTIONS ...... …. 67

5.1- DOWNTIME DISTRIBUTIONS ...... 67

5.2- ANALYTICAL MAINTAINABILITY
ENGINEERING FUNCTIONS ANALOGOUS

TO THOSE IN RELIABILITY ENGINEERING ...... 77

CHAPTER 6- MAINTAINABILITY AND ITS QUANTIFICATION ...... 91

6.1- MAINTAINABILITY DEFINED ...... 91

6.2- THE EXPONENTIAL CASE ...... 93

6.3- THE REPAIR RATE, μ...... 97

6.4- THE MEAN TIME TO REPAIR, MTTR ...... 97

6.5- MEAN ACTIVE CORRECTIVE

MAINTENANCE TIME, ...... 99

6.6- MEAN ACTIVE PREVENTIVE

MAINTENANCE TIME, ...... 100

6.7- MEAN ACTIVE CORRECTIVE AND

PREVENTIVE MAINTENANCE TIME, tM ...... 100
6.8- EQUIPMENT REPAIR TIME, ERT ...... 101
6.9- GEOMETRIC MEAN TIME

TO REPAIR, MTTRG ...... 101

6.10- MAXIMUM MAINTENANCE TIME, ...... 102

6.11- THE LOGNORMAL CASE ...... 106

6.12- MAINTAINABILITY FOR GIVEN
RESTORATION TIME WITH A WEIBULL

TIMES-TO-RESTORE DISTRIBUTION ...... 111

6.13- TIME TO RESTORE FOR GIVEN
MAINTAINABILITY WITH A WEIBULL

TIMES-TO-RESTORE DISTRIBUTION ...... 112

6.14- A PRIORI VERSUS A POSTERIORI

MAINTAINABILITY DETERMINATION ...... 114

CHAPTER 7- STEADY STATE MEAN TIMES TO ACTIVELY

RESTORE, REPAIR AND/OR REPLACE

COMPONENTS IN AN EQUIPMENT ...... 123

7.1- MEAN TIME TO ACTIVELY RESTORE AN EQUIPMENT ...... 123
7.2- EQUIPMENT RESTORATION TIME,

EFFICIENCY AND CONSISTENCY ...... 125

7.3- MEAN MAINTENANCE MAN-HOURS ...... 128
7.4- MEAN MAINTENANCE MAN-HOURS TO

REPAIR AND REPLACE AN EQUIPMENT ...... 129

7.5- MEAN TIME FOR CORRECTIVE AND

PREVENTIVE MAINTENANCE ...... …. 137

CHAPTER 8- MAINTAINABILITY ENGINEERING
SPECIFICATIONS AND

THEIR APPLICATIONS ...... 147

8.1- GOVERNMENT MAINTAINABILITY SPECIFICATIONS ...... 147
8.2- MIL - STD - 470 ...... 148
8.3- MIL - STD - 471 ...... 148
8.4- TEST METHOD 1 - TEST OF THE MEAN ...... 150

8.5- TEST METHOD 2 - TEST ON CRITICAL PERCENTILE ...... 158

8.6- TEST METHOD 3 - TEST ON CRITICAL

MAINTENANCE TIME OR MAN-HOURS ...... …………... 163

8.7- TEST METHOD 4 - TEST ON MEDIAN, ERT 169

8.8- TEST METHOD 5 - TEST ON CHARGEABLE

MAINTENANCE DOWNTIME

PER FLIGHT ...... 171

8.9- TEST METHOD 6 - TEST ON MAN-HOUR RATE ...... 178

8.10- TEST METHOD 7 - TEST ON MAN-HOUR RATE

USING SIMULATED FAULTS ...... 179

8.11- TEST METHOD 8 - TEST ON A COMBINED

MEAN/PERCENTILE REQUIREMENT ...... 183

8.12- TEST METHOD 9 - TEST FOR MEAN

MAINTENANCE TIME AND Mmax ...... 191

8.13- TEST METHOD 10 - TESTS FOR PERCENTILES

AND MAINTENANCE TIME (CORRECTIVE

OR PREVENTIVE MAINTENANCE) ...... 196

8.14- TEST METHOD 11 - TESTS FOR PREVENTIVE

MAINTENANCE TIMES ...... 199

CHAPTER 9- PREVENTIVE MAINTENANCE AND ITS

QUANTIFIED ADVANTAGES ...... 243

9.1- PREVENTIVE MAINTENANCE CONCEPTS ...... 243
9.2- PREVENTIVE MAINTENANCE BY

AGE REPLACEMENT-POLICY I ...... 244

9.3- THE CASE OF THE SINGLE EXPONENTIAL

UNIT SUBJECTED TO PREVENTIVE

MAINTENANCE ...... 253

9.4-CORRECTIVE FAILURE RATE AND
PREVENTIVE REPLACEMENT RATE

FOR POLICY I ...... 269

9.5- TOTAL AVERAGE NUMBER OF SPARES FOR

FOR POLICY I ...... 273
9.6- MINIMUM COST PREVENTIVE MAINTENANCE

PERIOD, Tp, FOR POLICY I ...... 274
9.7- PREVENTIVE MAINTENANCE BY

BLOCK REPLACEMENT-POLICY II ...... 275

9.8- PREVENTIVE MAINTENANCE BY

REPLACING GROUPS OF PARTS ...... 284

CHAPTER 10- PERIODIC REPLACEMENT POLICIES ...... 335
10.1- ORDINARY PERIODIC REPLACEMENT

POLICY-POLICY III ...... 335

10.2- MODIFIED PERIODIC REPLACEMENT

POLICIES-POLICIES IV, V, VI ...... ….. 338

CHAPTER 11- MODIFIED BLOCK REPLACEMENT

POLICIES ...... 359

11.1- ORDINARY BLOCK REPLACEMENT

POLICY-POLICY VII ...... 359

11.2- MODIFIED BLOCK REPLACEMENT

POLICY-POLICY VIII ...... 361

CHAPTER 12- ADDITIONAL MAINTENANCE POLICIES ...... ……………… 385
12.1- OPTIONAL REPLACEMENT POLICY-POLICY XI ...... 385

12.2- MULTISTAGE REPLACEMENT POLICY-POLICY XII ...... 402

12.3- OPPORTUNISTIC REPLACEMENT POLICY-POLICY XIII ...... 413

12.4- PREVENTIVE REPLACEMENT POLICY

FOR CAPITAL EQUIPMENT-POLICY XIV ...... 433

12.5- OPTIMAL INSPECTION FREQUENCY:

MAXIMIZATION OF PROFIT-POLICY XV ...... 438

12.6- OPTIMAL INSPECTION INTERVAL:

MAXIMIZATION OF EQUIPMENT

AVAILABILITY - POLICY XVI ...... 441

12.7- A SUMMARY OF RECENT DEVELOPMENTS

IN MAINTENANCE POLICIES ...... 446

CHAPTER 13- OVERHAUL POLICIES ...... 461
13.1- OVERHAUL ...... 461
13.2- OVERHAUL DEFINED ...... 463

13.3- DYNAMIC PROGRAMING BASICS ...... 477
13.4- OPTIMAL OVERHAUL/REPAIR/REPLACE

POLICY: FINITE TIME HORIZON ...... 478

13.5- OPTIMAL OVERHAUL/REPAIR/REPLACE

POLICY: INFINITE TIME HORIZON ...... 495

13.6- OPTIMAL COST LIMITS: FINITE TIME

HORIZON ...... 501

CHAPTER 14- SPARES PROVISIONING ...... 533
14.1- SPARES PROVISIONING AT A DESIRED

CONFIDENCE LEVEL ...... 533

14.2- SPARES PROVISIONING FOR A

DECAYING POPULATION ...... 544

14.3- SPARES PROVISIONING WHEN REPLACING

UNITS THAT FAIL BY A PRESCRIBED

OPERATING TIME ...... 546

14.4- PREVENTIVE MAINTENANCE POLICIES

AND SPARES PROVISIONING ...... 551

14.5- SPARES PREDICTION WITH GROWTH AND

WARRANTY ...... 573

14.6- SPARES PROVISIONING WITH COST OF

SPARES CONSIDERATION ...... 583

14.7- SPARES PROVISIONING AND INVENTORY

COSTS CONSIDERATION ...... 609

14.8- COST AND CRITICALITY OF SPARES

CONSIDERATION ...... 625

CHAPTER 15- DISTRIBUTIONAL TEST AND REPAIR TIMES

IN A TEST AND REPAIR FACILITY ...... 635
15.1- HOW TO APPLY ...... 635

15.2- GENERATION OF RANDOM VALUES FOR

VARIOUS DISTRIBUTIONS ...... 671
15.3- ERROR BOUNDS AND NUMBER OF

MONTE CARLO TRIALS ...... 673
15.4- CONCLUDING REMARKS ...... 679

CHAPTER 16- THE WEIBULL PROCESS OF

REPAIRABLE UNITS ...... 697
16.1- THE WEIBULL PROCESS AND ITS CHARACTERISTICS ...... 697

16.2- THE ESTIMATION OF A WEIBULL PROCESS ...... 701

16.3- WHEN TESTING MORE THAN ONE UNIT ...... 711

16.4- THE COMPOSITE WEIBULL PROCESS ...... 721

CHAPTER 17- RELIABILITY OF COMPONENTS

WITH A POLICY OF REPLACING
THOSE THAT FAIL BY A

PRESCRIBED OPERATING TIME ...... 739

17.1- WHEN AND HOW IT IS APPLIED ...... 739

CHAPTER 18- RELIABILITY OF MAINTAINED EQUIPMENT

WHEN KEEPING TRACK OF THE AGES OF
ALL COMPONENTS WITH EXPONENTIAL

AND WEIBULLIAN PDF 'S ...... 755

18.1- RELIABILITY WHILE KEEPING TRACK OF THE AGES

OF ALL COMPONENTS ...... 755
18.2- MEAN LIFE ...... 757

INDEX ...... 769
ABOUT THE AUTHOR ...... 777

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